Mustang ML28 All Wheel Steer Loader Operator's Manual 918131 - PDF DOWNLOAD

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ML28 Beginning Serial Number: 341020017

ALL-WHEEL-STEER LOADER

OPERATOR’S MANUAL PART #918131 Revision B - 02/07

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Mustang Manufacturing Company, Inc.

MUSTANG MANUFACTURING COMPANY, INC. WARRANTY MUSTANG MANUFACTURING COMPANY, INC., hereinafter referred to as Mustang, warrants new Mustang equipment to the Original Retail Purchaser to be free from defects in material and workmanship for a period of twelve (12) months from the Warranty Start Date.

MUSTANG WARRANTY SERVICE INCLUDES: Genuine Mustang parts and labor costs required to repair or replace equipment at the selling dealer's business location.

MUSTANG MAKES NO REPRESENTATIONS OR WARRANTIES OF ANY KIND, EXPRESS OR IMPLIED (INCLUDING THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR PARTICULAR PURPOSE), EXCEPT AS EXPRESSLY STATED IN THIS WARRANTY STATEMENT. ANY OF THESE LIMITATIONS EXCLUDED BY LOCAL LAW SHALL BE DEEMED DELETED FROM THIS WARRANTY; ALL OTHER TERMS WILL CONTINUE TO APPLY. SOME STATES DO NOT PERMIT THE EXCLUSION OR LIMITATION OF THESE WARRANTIES AND YOU MAY HAVE GREATER RIGHTS UNDER YOUR STATE LAW. MUSTANG WARRANTY DOES NOT INCLUDE: 1. Transportation to selling dealer's business location or, at the option of the Original Retail Purchaser, the cost of a service call.

2. Used equipment.

3. Components covered by their own non-Mustang warranties, such as tires, batteries, trade accessories and engines.

4. Normal maintenance service and expendable, high-wear items.

5. Repairs or adjustments caused by: improper use; failure to follow recommended maintenance procedures; use of unauthorized attachments; accident or other casualty.

6. Liability for incidental or consequential damages of any type, including, but not limited to lost profits or expenses of acquiring replacement equipment.

No agent, employee or representative of Mustang has any authority to bind Mustang to any warranty except as specifically set forth herein.

Table of contents Table of contents

Table of contents

Table of contents Introduction ........................................................................................................................ 3 General information ..................................................................................................... 3 Identification of warnings and hazards ........................................................................ 6 Machine overview ........................................................................................................ 7 Overview ...................................................................................................................... 8 Fields of application, attachments ............................................................................... 9 Serial number plate locations .................................................................................... 10 Fire extinguisher (option) ........................................................................................... 13 Safety instructions ............................................................................................................ 15 General safety rules ................................................................................................... 17 Additional safety equipment ....................................................................................... 19 Safety reminders ........................................................................................................ 19 Transporting ............................................................................................................... 20 Loading and transporting the machine ...................................................................... 22 Maintenance safety .................................................................................................... 24 Safety instructions for specific hazards ..................................................................... 27 Operation ......................................................................................................................... 33 Description of controls ............................................................................................... 33 Cab: overview ............................................................................................................ 34 Instrument panel, multifunctional lever, drive lever: overview .................................. 36 Indicators and warning lights: overview .................................................................... 37 Getting started ........................................................................................................... 39 Starting the engine ..................................................................................................... 43 Before driving the machine ........................................................................................ 46 Parking the machine .................................................................................................. 51 Differential lock .......................................................................................................... 51 Load stabilizer (option) .............................................................................................. 52 Backup warning system ............................................................................................. 53 Light system ............................................................................................................... 54 Working light (option) ................................................................................................. 55 Rotating beacon (option) ........................................................................................... 55 Interior light ................................................................................................................ 56 Signaling system ........................................................................................................ 56 Cab heating and ventilation ....................................................................................... 57 Rear window heater ................................................................................................... 57 Windshield washer system ........................................................................................ 58 Operator's seat .......................................................................................................... 60 Seat belt ..................................................................................................................... 62 Doors and side windows ............................................................................................ 64 Engine cover .............................................................................................................. 66 Other controls ............................................................................................................ 67 Removing the cab for low clearance heights ............................................................. 68 ROPS bar (option) ..................................................................................................... 69 Working with the machine .......................................................................................... 71 Re-installing the attachments .................................................................................... 75 High flow front control circuit ...................................................................................... 78 Hose burst valve safety feature (option) .................................................................... 79 Working with the standard bucket .............................................................................. 80 Working with the pallet forks ...................................................................................... 86 Working with the multipurpose bucket ....................................................................... 93 Working with the Skid-A-TachTM adapter (option) .................................................. 101 Troubleshooting ............................................................................................................. 103 Engine trouble ......................................................................................................... 103

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Table of contents Maintenance ...................................................................................................................105 Introduction ..............................................................................................................105 Fuel system ..............................................................................................................105 Engine lubrication system ........................................................................................107 Engine and hydraulics cooling system .....................................................................109 Air filter .....................................................................................................................111 V-belt ........................................................................................................................113 Hydraulic system ......................................................................................................114 Checking hydraulic pressure lines ...........................................................................117 Lubrication points .....................................................................................................119 Tire care ...................................................................................................................122 Electrical system ......................................................................................................124 General maintenance work ......................................................................................126 Fluids and lubricants ...............................................................................................129 Maintenance schedule Model ML28 (overview) .......................................................131 Maintenance log .......................................................................................................135 Maintenance decal ...................................................................................................139 Specifications .................................................................................................................141 Frame .......................................................................................................................141 Engine ......................................................................................................................141 Power train ...............................................................................................................142 Axles ........................................................................................................................142 Brakes ......................................................................................................................143 Steering ....................................................................................................................143 Loader hydraulics .....................................................................................................143 Pilot control ..............................................................................................................144 Additional high flow control circuit (option) ...............................................................144 Electrical system ......................................................................................................145 Tires ........................................................................................................................147 Weights ...................................................................................................................147 Noise levels .............................................................................................................147 Vibration ..................................................................................................................148 Coolant compound table ..........................................................................................148 Tightening torques ...................................................................................................148 Loader unit ...............................................................................................................149 Dimensions ..............................................................................................................150

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Introduction

Introduction

Introduction General information Your decision to purchase this piece of Mustang equipment was a good one. We are sure that your decision was carefully considered and that you are looking forward to many years of reliable performance from this machine.

Mustang Company has invested much time and effort in developing its lines of equipment.

The equipment you have purchased is built with a great deal of pride, and designed to provide long life, efficient operation, durability and dependability.

Modern machinery has become more sophisticated and, with that in mind, Mustang Company asks that you read and COMPLETELY understand the contents of this manual and become familiar with your new machine, BEFORE attempting to operate it.

This manual was developed specifically for the machine you have purchased. The information within is for your assistance in preparing, adjusting, maintaining and servicing your machine. More importantly, this manual provides an operating plan for safe and proper use of your machine. Major points of safe operation are detailed in the SAFETY chapter of this manual – see Safety instructions on page 15. Refer to the Table of Contents for an outline (by chapters) of this manual. Use the Index, located at the back of this manual, for specific chapter and topic/page number references.

If this machine is resold, Mustang Company recommends that this manual be given to the new owner.

If this machine was purchased "used," or if the owner's address has changed, please provide your Mustang dealer or Mustang Company with the owner's name and current address, along with the machine model and serial number. This will allow the registered owner information to be updated, so that the owner can be notified directly in case of an important product issue, such as a safety update program.

“Right” and “left” are determined from the position of sitting in the operator’s seat, facing forward.

Mustang Company reserves the right to make changes or improvements in the design or construction of any part without incurring the obligation to install such changes on any unit previously delivered.

Throughout this manual information is provided that is introduced by the word NOTE or IMPORTANT. Be sure to read carefully and comply with the message or directive given.

Following this information will improve your operating or maintenance efficiency, help you to avoid costly breakdowns or unnecessary damage and extend your machine's life.

Operational safety and readiness of the machine depend partially on maintenance and service of the machine. This is why regular maintenance and service work is absolutely necessary. Extensive maintenance and repair work must always be carried out by a qualified technician with appropriate training. Insist on using Mustang original service parts when carrying out maintenance and repair work. This ensures operational safety and readiness of your machine, and maintains its value.

Our wide dealership network stands ready to provide any assistance required, including genuine Mustang service parts. All parts should be obtained from or ordered through your Mustang dealer. Give complete information about the part as well as the model number and serial number of your machine. Record numbers, in the spaces provided, as a handy record for quick reference.

Purchased from: ___________________________________ Date of Purchase: __________________________________ Model No.: _______________________________________ Serial No.: ________________________________________ Printed in U.S.A.

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Introduction Serial number The serial number is stamped onto the machine frame (fig. 1/A), and is also located on the type decal (fig. 2).

The type decal is located at the front right of the frame (on one side of the cab bulkhead).

A

Type decal information Example: Model ML28

Type decal: location

KRAMER-WERKE GMBH

Made in Germany

00 435 12 21

Fig. 1:

ML28

Version:

342 01

Serial no.: Model year:

342 01 0090 2004

Front gross axle weight rating: 3527 lbs. (1600 kg) Rear gross axle weight rating: 3527 lbs. (1600 kg)

D - 88662 berlingen / Bodensee

Fhzg-Typ Model ModŁle Typ / Ausf.

Version Version Fg.-Nr. Serial no.

No. de sØrie Baujahr Model year AnnØe fabr.

Machine model:

Zul. Achslast vorn Front GAWR [ kg ] PNBE AV Zul. Achslast hinten Rear GAWR [ kg ] PNBE AR Zul. Ges. Gew. GWR [ kg ] PTAC Leistung Output [ kW ] Performance

Gross weight rating: Output:

5071 lbs. (2300 kg) 38 hp (28 kW)

Other information– see Specifications on page 141.

30300b0010.eps

Fig. 2:

Type decal

Cab number The type decal (arrow) is located in the cab, on the top right frame member.

Fig. 3:

Cab type decal

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Introduction Designated uses and exemption from liability • The machine is intended for: • Moving earth, gravel, coarse gravel or ballast and rubble.

• Working with the attachments mentioned – see Fields of application, attachments on page 9.

• Every other use and attachment is not designated for this machine. Mustang will not be liable for damage resulting from any other use or attachment. The user alone will bear the risk.

• Follow the instructions in the Operator’s Manual, Maintenance and Service chapters, accident prevention regulations, safety and occupational regulations, and machine and traffic regulations. Mustang is not liable for damage resulting from the failure to follow these regulations.

• You can damage the machine by modifying it with parts, equipment, attachments and optional equipment that is not checked or released by Mustang. Mustang is not liable for damage resulting from the failure to follow these requirements.

• Mustang is not liable for personal injury and/or damage to property caused by failure to properly: • Operate.

• Transport.

• Service and perform maintenance.

• Repair the machine (in accordance with the Operator’s Manual).

• Read and understand the Operator’s Manual before starting, servicing, or repairing the machine. Follow the safety instructions.

• The machine may not be used for transport jobs on public roads.

• In applications with lifting gear, only use the machine according to its designated use.

Abbreviations/symbols • This symbol stands for a list.

• Subdivision within lists or an activity. Follow the steps in the recommended sequence.

☞ This symbol requires you to carry out the activity described. ➥ This symbol marks the passages in the text describing the effects or results of an activity.

n. s. = not shown.

“Option” = optional equipment. Stated whenever controls or other components of the machine are installed as an option.

This symbol shows the maneuvering direction – for better orientation in figures and graphics.

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Introduction Identification of warnings and hazards The following signal words are used throughout this manual and on decals on the machine to warn of potentially hazardous conditions.

DANGER!/WARNING!/CAUTION! Failure to follow the instructions identified by this symbol may result in personal injury or death for the operator or other persons.

☞ Measures for avoiding the hazard.

IMPORTANT! Failure to follow the instructions identified by this symbol may result in damage to the machine. ☞ Measures for avoiding damage to the machine.

NOTE: Contains instructions to help use the machine more efficiently.

Environment!

Failure to follow the instructions identified by this symbol may result in damage to the environment.

The environment can be damaged if hazardous material (e.g., waste oil) is not properly used or disposed.

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Introduction Machine overview

1

Rearview mirror

2

Handle

3

Headlights

4

Warning decal

5

Turn indicator

6

Step

7

Door handle and lock

8

Door arrester

9

Front eye hook for tieing down the machine

8

1 2

13

3

4

9

1

17 16

2 7

5

6

7

10

Reflectors

11

Turn indicator/brake/rear light

12

Towing device/eye hook for loading/ tieing down the machine

13

High-flow auxilary hydraulic connections (option)

14

Engine cover lock

15

Warning (Do not open engine cover)

16

Working light

17

Rotating beacon (option)

18

Rear eye hooks for tieing down the machine

15 14

10

18

11

12 Fig. 4:

Machine outside views

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Introduction Overview The Model ML28 is a versatile and powerful tool for moving earth, gravel and debris on construction sites and elsewhere – see Fields of application, attachments on page 9.

Equip the machine with the respective safety devices when using it as a lifting accessory – see Applications with lifting gear on page 18.

The main components of the machine are: • ROPS certified cab, enclosed version (standard).

• or ROPS bar (option).

• Water-cooled Yanmar four-cylinder diesel engine, 38 hp (28 kW) @ 2400 rpm.

• Sturdy steel frame; rubber-mounted engine.

• Hydrostatic drive with automatic drive control, inching valve; 12 mph (20 km/h) maximum speed.

• Hydraulic four-wheel power steering with emergency steering feature. The emergency steering feature, located inside the hydraulic system, allows you to steer the machine if you lose hydraulic or motor power.

• Front and rear planetary axles, rear axle with oscillation.

• Hydrostatic service brake (inching brake), mechanical disc-type parking brake.

Hydrostatic drive

The diesel engine drives a hydraulic pump, whose oil flow is sent to a hydraulic motor on the rear axle. The force of the hydraulic motor is transmitted to the rear axle via the transfer gearbox. At the same time, the front axle is driven by the cardan shaft, ensuring fulltime four-wheel drive.

Work hydraulics and hydrostatic four-wheel steering

The diesel engine also drives the joint gear pump for work hydraulics and hydrostatic fourwheel steering. The oil flow of this pump depends on the diesel engine speed only.

When the machine is in operation, the entire diesel engine output can be transmitted to the gear pump for work hydraulics and steering by using the inching valve. This valve responds as soon as the service brake is used, reducing or cutting off power input of the drive. Therefore, full engine output is available for the machine by pressing the accelerator pedal and the brake pedal at the same time.

Cooling system

A combined oil/water cooler (for the diesel engine and the hydraulic oil) is located at the rear of the machine.

The indicators on the instrument panel of the machine constantly monitor the engine and hydraulic oil temperatures, and the coolant temperature and level.

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Introduction Fields of application, attachments The attachments determine how the machine is used.

IMPORTANT! In order to avoid damage to the machine, only the attachments listed below have been certified for attachment to the machine.

☞ See Use: attachment.

Use: attachment

Possible attachments and material densities.

Description of attachment

Model

Stock number

Use

Standard bucket – normal material

ML28

809194

Loosening, picking up, transporting and loading loose or solid material (material density ≤ p=1.35 t/yd³ [≤ p=1.8 t/m³])

Light material bucket – lightweight material

ML28

809197

Picking up, transporting and loading very lightweight material (material density ≤ p=0.98 t/yd³ [≤ p=1.3 t/m³])

Pallet fork

ML28

809191

Picking up and transporting pallets

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Introduction Serial number plate locations Serial number The serial number is stamped onto the machine frame (fig. 5/A), and is also located on the type decal (fig. 6).

The type decal is located at the front right of the frame (on one side of the cab bulkhead).

A

Type decal information Example: Model ML28

Type decal: location

KRAMER-WERKE GMBH

Made in Germany

00 435 12 21

Fig. 5:

ML28

Version: Serial no.:

342 01 342 01 0090

Model year:

2004

Front gross axle weight rating: 3527 lbs. (1600 kg) Rear gross axle weight rating: 3527 lbs. (1600 kg) Gross weight rating: 5071 lbs. (2300 kg)

D - 88662 berlingen / Bodensee

Fhzg-Typ Model ModŁle Typ / Ausf.

Version Version Fg.-Nr. Serial no.

No. de sØrie Baujahr Model year AnnØe fabr.

Machine model:

Zul. Achslast vorn Front GAWR [ kg ] PNBE AV Zul. Achslast hinten Rear GAWR [ kg ] PNBE AR Zul. Ges. Gew. GWR [ kg ] PTAC Leistung Output [ kW ] Performance

Output:

38 hp (28 kW)

Other information– see Specifications on page 141.

30300b0010.eps

Fig. 6:

Type decal

Cab number The type decal (arrow) is located in the cab, on the top right frame member.

Fig. 7:

Cab type decal

Engine number The type decal (arrow) is located on the engine cylinder-head cover.

Example:

Fig. 8:

Yanmar 46557

Diesel engine number

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Introduction Hydraulic pump number The type decal (arrow) is located on the hydraulic pump housing (next to where the pump is attached to the diesel engine).

Example:

Fig. 9:

6204226

Hydraulic pump: type decal

Hydraulic motor number The type decal (arrow) is located above the cardan shaft, on the right of the hydraulic motor.

Example:

7657648

Fig. 10: Hydraulic motor: type decal

Rear axle number The type decal (arrow) is located on the differential housing, at the rear.

Fig. 11: Rear axle and gearbox: type decal

Front axle number The type decal (arrow) is located on the differential housing, at the front.

Fig. 12: Front axle: type decal

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Introduction Safety decals The following section explains signs and symbols that may not be easily understood.

IMPORTANT! Safety decals must be replaced if they become unreadable.

Meaning The cab eye hooks may not be used for crane-lifting and loading the machine – see Crane handling on page 21.

Location Cab roof (4 x).

Fig. 13: Eye hook decal

Meaning Points for tieing down the machine.

The eye hooks are used for tieing down the machine during loading and transport – see Tieing down the machine on page 23.

Location On the left and right of the machine frame above the front axle attachment, and on the towing facility at the rear.

Fig. 14: Decal for points used for tieing down the machine

Meaning Noise levels produced by the machine.

LWA = sound power level.

Other information – see Noise levels on page 147.

XX

Location Rear window.

Fig. 15: Decal: noise levels

Meaning General indication of danger.

This decal warns persons standing or working near the machine of existing hazards within the area of increased danger around the machine.

Location Gefahr2.ai

Front left and right of machine frame, and at rear of machine.

Fig. 16: Danger decal

Meaning The CE mark means that the machine meets the requirements of the Machinery Directive and that the conformity procedure has been carried out. The machine meets all the health and safety requirements of the Machinery Directive.

Location ce.ai

On the rear window.

Fig. 17: CE mark

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Introduction Meaning DO NOT open engine cover before engine is at a standstill.

DO NOT touch any moving or turning parts.

Location On the engine cover of the machine.

Fig. 18: Prohibitory decal

Fire extinguisher (option) The fire extinguisher is not included in the machine's standard equipment. ☞ Location: 9.8” (250 mm)

2.0”

(50 mm )

➥ Inside the cab, at the rear left (see figure).

Fig. 19: Fire extinguisher (option)

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Introduction Notes:

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Safety instructions

Safety instructions

Safety instructions Mandatory safety shutdown procedure

Before operating this equipment, read and study the following safety information. In addition, be sure that every individual who operates or works with this equipment is familiar with these safety precautions.

Before leaving the machine: • Lower the working equipment to the ground and support it securely.

• Reduce throttle and turn off the engine.

• Lock out controls by raising right-hand control console.

• Remove the ignition key and take it with you.

Unauthorized modifications

Any machine modification made without authorization from Mustang could create a safety hazard, for which the machine owner would be responsible.

For safety reasons, use only genuine Mustang parts. For example, using incorrect fasteners could lead to a condition in which the safety of critical assemblies is dangerously compromised.

Attachment precautions

Optional kits are available through your dealer. Because Mustang cannot anticipate, identify and test all of the attachments that owners may wish to install on their machines, please contact Mustang for information on approval of attachments, and their compatibility with optional kits.

Operational safety

Control the machine cautiously and gradually until you are fully familiar with all the controls and handling.

Avoid high-voltage lines. Serious injury or death can result from contact or proximity to high-voltage electric lines. The bucket or boom does not have to make physical contact with power lines for current to be transmitted. Use a spotter and hand signals to keep away from power lines not clearly visible to the operator.

Depending upon the voltage in the line and atmospheric conditions, strong current shocks can occur if the boom or bucket closer than 10 ft. (3 m) to the power line. Very high voltage and rainy weather can further increase the safe operating distance.

Before starting any type of operation near power lines (either above-ground or buried cable-type), always contact the power utility and establish a safety plan with them.

Before starting to dig, contact authorities. Contact Diggers Hotline One-Call Information at 1-888-258-0808.

Below-ground hazards also include natural gas lines, water mains, tunnels and buried foundations. Know what is underneath the work site before starting to dig.

Be aware of height obstacles. Any object in the vicinity of the boom could represent a potential hazard, or cause the operator to react suddenly and cause an accident. Use a spotter or signal person when working near bridges, phone lines, work site scaffolds, or other obstructions.

Use care on loose ground. Carrying heavy loads over loose, soft ground or uneven, broken terrain can cause dangerous side-load conditions and possible tipover and injury.

Traveling with a suspended load or an unbalanced load can also be hazardous.

If temperatures are changing, be cautious of dark and wet patches when working or traveling over frozen ground. Stay away from ditches, overhangs and other weak support surfaces.

Never rely on jacks or other inadequate supports when maintenance work is being done.

Use solid support blocking.

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Safety instructions Overhangs are hazardous. Digging under an overhang is dangerous. Know the height and reach limits of the attachment and plan ahead while working. Avoid creating dangerous situations caused by moving around the work site while working. Move to another digging area before large overhangs are formed. Working around deep pits or along high walls or trenches may require support, especially after heavy rainfalls or during spring thaws. Park the machine away from overhangs.

Sloping terrain requires caution. Dig evenly around the work site whenever possible, trying to gradually level any existing slope. If it is not possible to level the area or avoid working on a slope, reduce the cycling rate and size of the load.

On sloping surfaces, use caution when positioning the machine prior to starting a work cycle. Stay alert for instability situations. Lifting the bucket too high while the boom is turned uphill can also be hazardous.

Stay alert for people moving through the work area. When loading a truck you should always know where the driver is.

Avoid loading over the cab of a truck, even if the driver is in a safe spot, because someone else could have gone inside.

Slow down the work cycle and use slower travel speeds in congested or populated areas.

Use commonly understood signals so that other members of the work crew can warn the operator to slow or halt work in a potentially hazardous situation.

Operate ONLY while seated at operator’s station. Never reach in through a window to work a control. Do not try to operate the machine unless you’re in the operator’s position, seated at the controls. Stay alert and focused on your work at all times.

Use a signal person if you cannot see the entire work area clearly.

Replace damaged safety decals and lost or damaged Operator’s Manuals.

Do not let anyone operate the machine unless they have been fully trained in safety and in operation of the machine.

DO NOT raise or lower a loaded bucket suddenly. Abrupt movements under load can cause serious instability.

Before starting the engine

Do a safety check: • Walk around the machine before getting in the cab. Look for leaking fluids, loose fasteners, misaligned assemblies and other possible equipment hazards.

• The operator’s compartment, steps, and hand grips must be free of oil, dirt, ice and unsecured objects.

• The lighting system must be checked for proper working condition before working in darkness.

• Always keep the windshield and windows clean. Poor visibility can cause accidents.

• All equipment covers and safety guards must be in place while the machine is being operated, to protect against injury.

• Look around the work site area for potential hazards, and for people or property that could be at risk while operation is in progress.

• NEVER start the engine if there is any indication that maintenance or service work is in progress, or if a warning tag is attached to controls in the cab.

• Check gauges and displays for normal operation prior to and after starting the engine.

Listen for unusual noises and remain alert for other potentially hazardous conditions.

• Never use ether starting aids. Glow plugs are used for cold weather starting. Glow plugs can cause ether or other starting fluid to detonate, causing injury.

• Before starting or moving the machine, warn any personnel in the area.

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Safety instructions General safety rules Only trained and authorized personnel, with a full awareness of safe procedures, may be allowed to operate or perform maintenance or service on the machine.

All personnel at the work site should be aware of assigned individual responsibilities. Communication and hand signals used should be understood by everyone.

Terrain and soil conditions at the job site, approaching traffic, weather-related hazards and any above-or below-ground obstacles and hazards should be observed and monitored by all work crew members.

Unless necessary for servicing the engine, the engine hood must not be opened while the engine is running.

Engine exhaust gases can cause unconsciousness and fatalities. Ensure adequate ventilation before starting the engine in an enclosed area.

Operators should also be aware of any open windows, doors or ductwork into which exhaust gases may be carried, exposing others to danger.

Use a signal person in high traffic areas and whenever the operator’s view is not clear, such as when traveling in reverse.

Make sure that no one comes inside the working area of the machine.

Anyone standing near the machine is at risk of being caught between moving parts of the machine.

Never allow anyone to ride on any part of the machine or attachment, including any part of the boom or operator’s cab.

Fire hazards

The machine has several components that operate at high temperature under normal operating conditions, primarily the engine and exhaust systems. Also, the electrical system, if not properly maintained or if damaged, can arc or produce sparks. These conditions make it extremely important to avoid circumstances where explosive dust or gases can be ignited by arcs, sparks or heat.

The machine must be cleaned on a regular basis to avoid the buildup of flammable debris such as leaves, straw, etc. Accumulated debris, particularly in the engine compartment, poses a fire hazard.

Add fuel, oil, antifreeze and hydraulic fluid to the machine only in a well ventilated area.

The machine must be parked with controls, lights and switches turned off. The engine must be turned off before refueling or service checks are performed.

Static electricity can produce dangerous sparks at the fuel-filling nozzle. In very cold, dry weather or other conditions that could produce static discharge, keep the tip of the fuel nozzle in constant contact with the neck of the fuel-filling nozzle, to provide a ground.

Make sure that the static line is connected from the machine to the service truck before fueling begins.

Keep fuel and other fluid reservoir caps tight and do not start the engine until caps have been secured.

Jump-starting or charging battery

Turn off all electrical equipment before connecting leads to the battery, including electrical switches on the battery charger or jump-starting equipment.

When jump-starting from another machine, do not allow the machines to touch. Wear safety glasses or goggles while battery connections are made.

DANGER! Explosion Hazard – Electrical spark can cause battery to explode.

Connect positive cable first when installing jumper cables. The final cable connection, at the metal frame of the machine being charged or jump-started, should be as far away from the batteries as possible.

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Safety instructions Disconnect the negative cable first when removing the jumper cables. For instructions – see Battery on page 125.

Travel precautions

Loader control lever should not be operated while traveling. Be sure to lock out the control lever during travel.

IMPORTANT! Do not change selected travel mode (FAST/SLOW) while traveling.

Travel with the bucket or attachment as low as possible [8”-12” (200 mm-300 mm)] to the ground.

Never travel over obstacles or slopes that will cause the machine to tilt severely. Travel around any slope or obstacle that would cause a tilt greater than 10º.

Operate carefully on snow and ice and in very cold temperatures.

In cold weather, avoid sudden travel movements and stay away from even very slight slopes. The machine can slide sideways on icy slopes.

Snow accumulation can hide potential hazards. Use care while operating and while using the machine to clear snow.

Parking the machine

When shutting down the machine for the day, plan ahead so that the machine will be on a firm, level surface away from traffic and away from high walls, cliff edges and any area of potential water accumulation or runoff. If parking on an incline is unavoidable, block the wheels to prevent movement. Lower the bucket to the ground. There should be no possibility of unintended or accidental machine movement.

After the machine has been parked properly, shut down the engine and cycle all controls to release any remaining hydraulic system pressure. Be sure all switches and operating controls are in the OFF position and the right-hand console is raised, locking out the hydraulic functions.

Applications with lifting gear

Definition: Applications with lifting gear are used for raising, transporting and lowering loads with the help of load-securing devices (e.g. slings, chains). In doing so, the help of persons is necessary for securing and detaching the load. For example, get help from other people when lifting and lowering pipes, culverts, or containers.

• The machine may only be used with lifting gear if the necessary safety devices are in place and functional.

• The load must be secured to prevent it from falling or slipping.

• Persons guiding the load or securing it must stay in visual contact with the operator.

• The operator must guide the load as soon as possible to the ground and avoid any oscillating or swinging movements.

• The machine may be moved with a raised load only if the path of the machine is as level as possible.

• Persons attaching or securing loads may only approach the boom from the side, after the operator has given permission. The operator may only give permission after the machine is at a standstill and the attachment no longer moves.

• DO NOT use any damaged or incorrectly dimensioned lifting attachments (slings, chains).

• Always wear protective gloves when working with lifting attachments.

Printed in U.S.A.

18

918131/BP0207

Safety instructions Additional safety equipment WARNING! Severe operation may require use of additional safety equipment.

Work in mines, tunnels, deep pits or on loose or wet surfaces could produce the hazard of falling rock, roll over or falling objects.

Any operator protective system installed on the machine must comply with applicable safety standards and carry appropriate decaling and rating information.

Never attempt to alter or modify the protective structure, by drilling holes, welding or relocating fasteners. Any serious impact or damage to the system requires a complete integrity re-evaluation, and the replacement of the system may be necessary.

Install additional safety equipment if conditions require

When working with a hydraulic breaker, a front guard over the windshield may be required.

Laminated glass or polycarbonate protection for the front, side or rear windows may also be recommended depending upon particular work conditions.

Contact your Mustang dealer for available safety guards and/or recommendations if there is any risk of being hit by objects that could strike the operator’s cab.

Keep a fire extinguisher at hand

It is recommended that a 5 lb. (2.27 kg) or larger, multi-purpose “A/B/C” fire extinguisher be mounted in the cab. Check the fire extinguisher periodically and be sure that work site crew members are trained in its use – see Fire extinguisher (option) on page 13.

Seat belt must be used at all times

When the engine is running, the operator must be seated at the control station with the seat belt fastened.

Safety reminders Exposure to crystalline silica

Exposure to crystalline silica (found in sand, soil and rocks) has been associated with silicosis, a debilitating and often fatal lung disease. A Hazard Review (Pub. No. 2002-129) by the U.S. National Institute for Occupational Safety and Health (NIOSH) indicates a significant risk (at least 1 in 100) of chronic silicosis for workers exposed to inhaled crystalline silica over a working lifetime. NIOSH recommends an exposure limit of 0.05 mg/m3 as a time-weighted average for up to a 10-hr workday during a 40-hr work week. NIOSH also recommends substituting less hazardous materials when feasible, using respiratory protection, and regular medical examinations for exposed workers.

Maintain safety equipment in good condition

Machinery guards and body panel covers must be in place at all times. Keep clear of rotating parts, such as cooling fan and alternator belts, which could catch hair, jewellery or loose clothing.

Safety-critical parts must be replaced periodically

Replace the following potentially fire-related components as soon as they begin to show signs of deterioration: Fuel system flexible hoses, fuel tank overflow drain hose and the fuel filler cap.

Hydraulic system hoses, especially the pump outlet lines.

Keep mounting brackets, hose, and cable routing ties tight. Hose routing should have gradual bends.

High pressure hydraulic lines can store energy

Exposed hydraulic hoses on the boom could react with explosive force if struck by a falling rock, overhead obstacle or other job site hazard. Extra safety guards may be required.

NEVER allow hoses to be hit, bent or interfered with during operation.

Operator’s cab should be kept clean

Cleaning off accumulations of grease and dirt helps extend equipment service life. Cleaning also provides an opportunity to inspect equipment. Minor damage can be repaired or corrected before major problems result.

Printed in U.S.A.

19

918131/BP0207

Safety instructions Wear eye protection and safety clothing

Full eye protection, a hard hat, safety shoes and gloves may be required at the job site.

Breathing masks, ear protection may be required

Do not forget that some risks to your health may not be immediately apparent. Exhaust gases and noise pollution may not be visible, but these hazards can cause permanent injuries.

Transporting Obey state and local over-the-road regulations. Check state and local restrictions regarding weight, width and length of a load. The hauling machine, trailer and load must all be in compliance with local regulations.

Towing and transporting the machine Safety instructions

• The machine may only be towed using a towing bar or a cable and towing facilities (for example, a towing coupling, hooks, and eyes).

• Tow slowly. Make sure no-one is near the towing bar.

• Only tow the machine with a cable if the service brakes and steering are fully operational.

Towing WARNING! Turning the steering wheel requires greater effort if the diesel engine breaks down. Remember this when towing the machine.

☞ Use a towing bar if the diesel engine breaks down.

IMPORTANT! The hydrostatic power train can be damaged when towing the machine. ☞ Turn off the engine.

☞ Short-circuit the hydraulic circuit before towing (see below). ☞ Do not tow the machine for more than 328 ft.(100 m) and do not tow it faster than 2 – 3 mph (3 – 4 k/mh).

A

D C B

Follow these procedures to tow the machine: ☞ Apply the parking brake – see Parking Brake on page 49.

☞ Turn off the engine. ☞ Attach an adequately sized towing bar to the towing facilities. ☞ Switch over pressure relief valves B on the hydraulic pump A. To do this: • Slacken hexagon locknuts C on both pressure relief valves B. • Screw in hexagon socket screws D on both pressure relief valves B until they are flush with hexagon locknuts C.

Fig. 20: Hydraulic pump when towing the machine

• Secure hexagon socket screws D on both pressure relief valves B with locknuts C.

☞ Release the parking brake. ☞ Run the engine at idling speed when towing the machine.

Follow these procedures before taking the machine back into service:

☞ Reverse the changeover of the pressure relief valves.

• Unscrew hexagon socket screws D on both pressure relief valves B to the limit.

• Secure hexagon lock nuts C on both pressure relief valves B.

Printed in U.S.A.

20

918131/BP0207

Safety instructions Moving the machine with a crane Safety instructions

• The crane and the lifting gear must have correct dimensions – see Specifications on page 141.

• Crane handling requires lifting gear of four equal lengths.

• Secure the machine against unintentional movement.

Crane handling WARNING! Incorrect crane handling of the machine –

Accident risk.

34101b330_01.iso

☞ Do not allow anyone to stay in the machine. ☞ The person giving the instructions to the crane operator must be within sight or sound of the crane operator.

☞ Make sure that the lifting capacities of the crane and the lifting gear (cables, chains) are sufficient.

☞ Only load the machine if the standard bucket is empty and in the transport position – see Fields of application, attachments on page 9. ☞ Avoid suspended loads.

Fig. 21: Crane handling

☞ Read the safety instructions – see Safety instructions on page 39.

☞ Load the machine as follows: • Install and safely lock the standard bucket – see Locking: Attachments without hydraulic function on page 76.

• Empty the standard bucket.

• Set the drive to neutral – see Select driving direction on page 50.

• Tilt in the standard bucket and lower it to the transport position – see Special instructions for public roads on page 46.

• Turn off the engine.

• Apply the parking brake – see Parking the machine on page 51.

• Remove the ignition key.

• Do not allow anyone to stay in the cab, close the doors and the engine cover.

• Fasten the loader at the three points provided by using proper lifting gear – see Machine overview on page 7.

WARNING! Do not use the cab eye hooks for loading the machine.

• Carefully raise the machine.

Printed in U.S.A.

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918131/BP0207

Safety instructions Loading and transporting the machine • The transport vehicle must support the height and weight of the machine – see Specifications on page 141.

Safety instructions

• Remove any dirt, snow, or ice from the tires.

• Secure the machine to prevent unintentional movement.

Loading the machine DANGER! The machine must be loaded and transported properly –

Accident risk. ☞ – see Safety instructions on page 15. ☞ Follow these instructions to load the machine onto the transport vehicle: • Secure the transport vehicle with chocks to prevent it from rolling.

30˚

• Place the access ramps at the smallest possible angle.

30864brampe.eps

Fig. 22: Access ramps

IMPORTANT! Do not exceed an angle of 30°.

• Use access ramps with an antiskid surface only.

• Make sure that the loading area is clear and access to it is not obstructed.

• Make sure that the access ramps and the wheels of the machine are free of oil, grease and ice.

• Start the engine of the machine.

• Raise the bucket so that it does not touch the access ramps.

• Carefully drive the loader onto the middle of the transport vehicle.

• Set the drive to neutral – see Select driving direction on page 50.

• Lower the bucket onto the loading area.

• Turn off the engine.

• Apply the parking brake – see Parking the machine on page 51.

• Remove the ignition key.

• DO NOT allow anyone to stay in the cab.

• Close the doors and the engine cover.

Printed in U.S.A.

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918131/BP0207

Safety instructions Tieing down the machine

DANGER! The machine must be loaded and transported properly –

Accident risk.

34001b330_02.eps

• Be sure that the authorized maximum height is not exceeded – see Specifications on page 141.

• Secure all tires of the machine with chocks in front of, behind, and at the sides of each wheel.

• Firmly tie the machine onto the platform by using the eye hooks and belts or chains – see Machine overview on page 7.

34001b330_17.eps Fig. 23: Tieing down the machine

Trailers and attachments

• Before transporting the machine through heavy rain, seal the muffler with a cap or adhesive tape.

• Be sure that the driver of the transport vehicle knows the overall height, width and weight of the vehicle (including the loader) before leaving.

• Attachments and counterweights affect handling, steering, and brake capability of the machine.

• Fit the attachments with the required devices only.

• Before uncoupling or coupling hydraulic lines (hydraulic quick couplers): • Turn off the engine.

• Move the control lever(s) of the hydraulic valve back and forth two times to reduce the hydraulic oil pressure in the hydraulic system.

• Coupling attachments requires special care.

• Secure the attachments against unintentional movement.

• Only operate the machine if all brake, light, hydraulic connections, and protective accessories are installed and functional.

• If optional equipment is installed, all required lights, indicators, etc., must be installed and functional.

• Mount the attachments only after stopping the engine.

• When driving or working with machines that have a quickhitch facility, make sure that the attachment is safely locked in the quickhitch facility. The lock pin must be visible on both sides of the holes on the attachment. Check before starting work.

• Before fitting attachments to the machine, secure the control lever of the hydraulic valve.

CAUTION! When mounting attachments to the machine, there is a risk of personal injury due to crushing and shearing. Make sure nobody is between the machine and attachment, after first securing the machine and attachment against movement.

Transport

• Only tow, load, and transport the machine in accordance with the Operator’s Manual.

• Safely secure the machine to the transport vehicle. Use suitable mounting points and load-securing devices.

Printed in U.S.A.

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918131/BP0207

Safety instructions Maintenance safety ☞ Use proper tools • While working on the machine, never use inadequate tools. They could break or slip, causing injury, or they may not adequately perform intended functions.

☞ Battery electrolyte and explosive gases can be lethal • Flush eyes with water for 10-15 minutes if battery acid is splashed in the face.

Anyone who swallows acid must have immediate medical aid. Call the Poison Control Center listing in the telephone directory.

• Sparks can set off explosive battery gas from incidental contact or static discharge.

Turn off all switches and the engine when working on batteries. Keep battery terminals tight. Contact between a loose terminal and post can create an explosive spark.

☞ Disconnect batteries for electrical service and before electrical welding • Remove cable to negative terminal first when disconnecting a battery. Connect positive terminal cable first when installing a battery.

☞ Use warning tag/control lockout procedures during service • Alert others that service or maintenance is being performed and tag operator’s cab controls — and other machine areas if required — with a warning notice. ☞ Do not run the engine if repairs or work is being performed alone • You should always have at least two people working together if the engine must be run during service.

☞ Always use adequate equipment supports and blocking • Lower bucket to the ground before leaving the operator’s seat. Do not work under any equipment supported solely by a lift jack. ☞ Do not work on hot engines, cooling or hydraulic systems • Wait for the engine to cool after operation. Park the machine on a firm, level surface and lower all equipment before shutting down and switching off controls. When engine lube oil, gearbox lubricant or other fluids require changing, wait for fluid temperatures to decrease to a moderate level before removing drain plugs.

IMPORTANT! Engine oil will drain more quickly and completely if it is warm. Do not drain hot fluids, e.g., 200° F (95° C), but do not wait for full cool-down either.

☞ Cool-down is required prior to radiator or hydraulic reservoir checks • Stop the engine and allow it to cool before performing service on the engine radiator or hydraulic reservoir. Both assemblies have pressure vents at the filler cap for venting pressure. LOOSEN CAPS SLOWLY. Vent the pressure before removing the filler caps.

• Release hydraulic system pressure by cycling controls and releasing hydraulic reservoir pressure before removing hydraulic reservoir access cover. The hydraulic reservoir is pressurized. Vent the system pressure by rotating the filler cap.

LOOSEN CAP SLOWLY prior to removal.

• Make sure to release stored hydraulic pressure in lines by cycling the operator’s controls in each direction after the engine has been shut down. ☞ Pressurized hydraulic oil leaks can be hazardous • Fluid leaks from hydraulic hoses or pressurized components can be difficult to see, but pressurized oil can have enough force to pierce the skin and cause serious injury.

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918131/BP0207

Safety instructions • Always use a piece of wood or cardboard to check for suspected hydraulic leaks.

Never use your hands. Obtain immediate medical attention if pressurized oil pierces the skin. Failure to obtain prompt medical assistance could result in gangrene or other serious damage to tissue.

☞ Use correct replacement fasteners tightened to proper torque • Refer to the Parts Manual for information on torques and assembly of components.

Always use the correct parts – incorrect fastener connections can dangerously weaken assemblies.

☞ Dispose of all petroleum-based oils and fluids properly • Used motor oil may pose a health risk. Wipe oil from your hands promptly and wash off any residue. Used motor oil is an environmental contaminant and may only be disposed of at approved collection facilities. Never drain any petroleum-based product on the ground or dispose of used oil in municipal waste collection containers, or in metropolitan sewer systems or landfills. Check state and local regulations for other requirements.

Safety instructions for maintenance • Remove the ignition key before performing any service, maintenance, or repair work.

• If you must have the engine running while performing service, maintenance, or repair work: • Only work in groups of two.

• Both persons must maintain visual contact with each other.

• Follow the safety instructions in the Operator’s Manual.

• Keep a safe distance away from all rotating and moving parts (e.g. fan blades, V-belt drives, etc.).

• Carry out service, maintenance and repair work only if the: • Machine is positioned on firm and level ground.

• Lever for selecting the travel direction is in neutral.

• Parking brake is applied.

• Hydraulic attachments and working equipment are lowered to the ground.

• Machine is secured against unintentional movement.

CAUTION! Avoid the risk of accidents by securing parts and large assemblies being moved to the lifting tackle. Stay clear of suspended loads.

CAUTION! Never use machine parts, attachments, or superstructures as a climbing aid.

Wear a safety harness when completing maintenance work at greater heights.

Keep all handles, steps, handrails, platforms, landings, and ladders free from dirt, snow and ice.

Printed in U.S.A.

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918131/BP0207

Safety instructions

IMPORTANT! Before cleaning the machine with water, a steam jet (high-pressure cleaning), or detergents, cover or tape up any openings that must be protected against water, steam or detergent penetration. Special care must be taken with the electrical system.

• After cleaning, examine all fuel, lubricant, and hydraulic oil lines for leaks, chafe marks and damage.

• Tighten any loose connections.

• Avoid contact with hot parts, such as the engine block or the exhaust system during the operation of the machine and for some time afterwards – danger of burns.

• Retainer pins can fly out or splinter when struck with force – danger of personal injury.

• Do not use ether starting aids. This especially applies to those cases in which a heater (intake-air preheating) is used at the same time – danger of explosions.

Service and maintenance work on ROPS superstructures (ROPS bar)

Printed in U.S.A.

• DO NOT do any straightening or welding work on ROPS structures. ROPS structures must be replaced by original Mustang service parts.

26

918131/BP0207

Safety instructions Safety instructions for specific hazards Electric energy

• Only use original fuses with the specified current rating. Turn off the machine immediately if there are any problems with the electrical system.

DANGER! When working with the machine, maintain a safe distance from overhead electric lines.

If work must be carried out close to overhead lines, keep the equipment/ attachments as far away from them as possible.

DANGER! If your machine comes into contact with a live wire: • Do not leave the machine.

• Drive the machine out of the area of danger.

• Warn others against approaching and touching the machine.

• Have the live wire de-energized.

• Do not leave the machine until the damaged line has been safely deenergized.

• Work on the electrical system may only be done by a trained technician.

• Inspect and check the electric equipment of the machine at regular intervals. Defects such as loose connections or scorched cables must be rectified immediately.

• Follow the operating voltage of the machine/attachments.

• Always remove the ground strap from the battery when working on the electrical system or carrying out welding work.

• Jump starting with a battery cable can be hazardous if carried out improperly. Follow the safety instructions regarding the battery.

Gas, dust, steam, smoke

Printed in U.S.A.

• Only operate the machine in adequately ventilated premises.

• Carry out welding, flame-cutting and grinding work on the machine only if this has been authorized. Before carrying out welding, flame-cutting and grinding work, clean the machine and its surroundings from dust and other flammable substances.

27

918131/BP0207

Safety instructions Hydraulic equipment

• Check all lines, hoses and connections regularly for leaks and damage. Repair any damage and leaks immediately. Splashed oil may cause injury and fire.

• Depressurize all system and pressure lines (hydraulic system) to be opened before carrying out any repair work.

• Hydraulic lines must be laid and fitted properly. Make sure no connections are interchanged. Use only genuine Mustang replacement parts to ensure that the fittings, lengths and quality of the hoses comply with the technical requirements.

Noise

• Maintain the muffler and exhaust system in good condition.

• Wear ear protectors if necessary.

Oil, grease and other chemical substances

• When handling oil, grease and other chemical substances (e.g., battery electrolyte – sulphuric acid), follow the product-related safety requirements (safety data sheet) carefully to prevent burning or scalding yourself or other persons.

Battery

• When handling the battery, follow the specific safety instructions. Batteries contain sulphuric acid and are caustic.

DANGER! A hydrogen-air mixture, which creates a risk of explosion, is formed in the battery cells during normal operation, and especially during charging.

In the case of a frozen battery or of an insufficient electrolyte level, do not try to start the machine with battery jumper cables. The battery can burst or explode.

Tires

• Repair work on tires and rims must be carried out only by technical staff or an authorized dealer.

• Damaged tires and/or wrong tire pressure reduce the operational safety of the machine. Therefore carry out regular checks of the tires for: • Proper tire pressure.

• Damage.

DANGER! DO NOT inflate tires with flammable gas – this creates a danger of explosion.

• Carry out regular checks of the wheel nuts for tightness. After changing tires, check the wheel nuts after 10 service hours.

Printed in U.S.A.

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918131/BP0207

Safety instructions Notes:

Printed in U.S.A.

29

918131/BP0207

CHECKLISTS I acknowledge the pre-delivery procedures were performed on this unit as outlined on this page.

Pre-Delivery Checklist

_______________________________________________

The following checklist is an important reminder of valuable information and inspections that MUST be made before delivering the machine to the customer. Check off each item after the prescribed action is taken.

Dealership Name _______________________________________________ Dealer Representative Name _______________________________________________ Date Checklist Filled Out

CHECK THAT: R

Unit has NOT been damaged in shipment. Check for such things as dents and loose or missing parts; correct or replace components as required.

R

Battery is securely mounted and NOT cracked. Be sure cable connections are tight.

R

Cylinders, hoses and fittings are NOT damaged, leaking or loosely connected.

R

Filters are NOT damaged, leaking or loosely secured.

R

Machine is properly lubricated and no grease fittings are missing or damaged.

R

Hydraulic system reservoir, engine crankcase and drive axles are filled to their proper levels.

R

All adjustments are made to comply with settings provided in the Maintenance chapter of this manual.

R

All guards, shields and decals are in place and secured.

R

Model and serial numbers for this unit are recorded in the space provided on this page.

_______________________________________________ Model & Serial Number

Delivery Checklist The following checklist is an important reminder of valuable information that MUST be passed on to the customer at the time of delivery. Check off each item as you explain it to the customer.

EXPLAIN: R

The Safety Instructions and Operation chapters of this manual, regarding the safe operation of this machine.

R

The Maintenance and Troubleshooting chapters for information regarding the proper maintenance of this machine.

Explain that regular lubrication and maintenance is required for continued safe operation and long machine life.

R

Give the Operator’s Manual to the customer and instruct the customer to read and completely understand the contents before operating the unit.

R

Completely fill out the Owner’s Registration, including customer’s signature and return it to the Mustang Company.

Start the engine and test run the unit while checking that all controls operate properly.

CHECK THAT: R

Drive controls and boom/bucket/steering controls operate properly and are not damaged or binding.

R

Drive controls are properly adjusted for correct neutral position.

Customer’s Signature

R

The parking brake, along with the lock-out devices, are activated with the unit stationary (no pilot control pressure).

_______________________________________________

R

All hydraulic boom functions are NOT operational with the control lever lock in the lock-out position.

_______________________________________________

Date Delivered

RETAIN FOR CUSTOMER’S RECORDS

Printed in U.S.A.

30

918131/AP1104

CHECKLISTS I acknowledge the pre-delivery procedures were performed on this unit as outlined on this page.

Pre-Delivery Checklist

________________________________________________

The following checklist is an important reminder of valuable information and inspections that MUST be made before delivering the machine to the customer. Check off each item after the prescribed action is taken.

Dealership Name ________________________________________________ Dealer Representative Name ________________________________________________ Date Checklist Filled Out

CHECK THAT:

Remove dealer’s file copy at perforation.

R

Unit has NOT been damaged in shipment. Check for such things as dents and loose or missing parts; correct or replace components as required.

R

Battery is securely mounted and NOT cracked. Be sure cable connections are tight.

R

Cylinders, hoses and fittings are NOT damaged, leaking or loosely connected.

R

Filters are NOT damaged, leaking or loosely secured.

R

Machine is properly lubricated and no grease fittings are missing or damaged.

R

Hydraulic system reservoir, engine crankcase and drive axles are filled to their proper levels.

R

All adjustments are made to comply with settings provided in the Maintenance chapter of this manual.

R

All guards, shields and decals are in place and secured.

R

Model and serial numbers for this unit are recorded in the space provided on this page.

________________________________________________ Model & Serial Number

Delivery Checklist The following checklist is an important reminder of valuable information that MUST be passed on to the customer at the time of delivery. Check off each item as you explain it to the customer.

EXPLAIN: R

The Safety Instructions and Operation chapters of this manual, regarding the safe operation of this machine.

R

The Maintenance and Troubleshooting chapters for information regarding the proper maintenance of this machine.

Explain that regular lubrication and maintenance is required for continued safe operation and long machine life.

R

Give the Operator’s Manual to the customer and instruct the customer to read and completely understand the contents before operating the unit.

R

Completely fill out the Owner’s Registration, including customer’s signature and return it to the Mustang Company.

Start the engine and test run the unit while checking that all controls operate properly.

CHECK THAT: R

Drive controls and boom/bucket/steering controls operate properly and are not damaged or binding.

R

Drive controls are properly adjusted for correct neutral position.

Customer’s Signature

R

The parking brake, along with the lock-out devices, are activated with the unit stationary (no pilot control pressure).

________________________________________________

R

All hydraulic boom functions are NOT operational with the control lever lock in the lock-out position.

________________________________________________

Date Delivered

RETAIN FOR DEALER’S RECORDS

Printed in U.S.A.

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918131/AP1104

INTENTIONALLY BLANK (To be removed as dealer’s file copy)

Printed in U.S.A.

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918131/AP1104

Operation

Operation

Operation Description of controls This chapter describes the indicators and controls in the cab.

The pages stated in the table refer to the description of the controls.

Number/letter combinations describe the controls, for example 40/18 or 34/A, means: page no. 40/control no. 18 or position A in fig. no. 34.

You can unfold pages 34, 36 for a better overview.

Cab overview: see overleaf

The following symbols are used: • This symbol stands for a list.

• Subdivision within lists or an activity. Follow the steps in the recommended sequence.

☞ This symbol requires you to carry out the activity described. ➥ This symbol marks the passages in the text describing the effects or results of an activity. n. s. = not shown.

“Option” = optional equipment.

Stated whenever controls or other components of the machine are installed as an option.

Printed in U.S.A.

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918131/BP0207

Operation 1

2

Cab: overview

3

Pos.

Description

For more information see page

Roof console 33 5

4

32

5

1

Sun visor

2

Switch – interior lighting..............................................................................................................................................................................56

3

Interior light.................................................................................................................................................................................................56

Cab 4

Instrument panel.........................................................................................................................................................................................36

5

Air vent – front window ...............................................................................................................................................................................56

6

Accelerator pedal........................................................................................................................................................................................48

7

Door locks...................................................................................................................................................................................................64

8

Multifunctional lever....................................................................................................................................................................... 54, 56, 58

9

Opener – side windows ..............................................................................................................................................................................64

10

Air vent – leg room...................................................................................................................................................................................... 57

11

Control lever – machine..............................................................................................................................................................................72

12 13

Arrester – side windows..............................................................................................................................................................................64 Fixture – first-aid kit

14

Control lever base................................................................................................................................................................................ 36, 67

15

Preheating start switch ...............................................................................................................................................................................43

16

Switch panel ............................................................................................................................................................................................... 54

10

17 18 19

Fuse box.................................................................................................................................................................................................. 145 Storage compartment/prepared radio installation (option) Prepared installation for loudspeakers (option)

28

11

20 21

Arrester – side window lock........................................................................................................................................................................64 Storage pocket for Operator’s Manual

27

12

22

Operator's seat ........................................................................................................................................................................................... 60

23

Lever – weight setting................................................................................................................................................................................. 60

31

6

30

7

7

8

9

9 I 0

12

13

26

14

25

15

24

16

23

17

22

18

21

19

20

20

24

Seat belt......................................................................................................................................................................................................62

25

Lever – horizontal seat adjustment.............................................................................................................................................................61

26

Parking brake lever.....................................................................................................................................................................................49

27

Backrest adjustment lever ..........................................................................................................................................................................61

28 29

Hydrostatic steering....................................................................................................................................................................................47 Not assigned

30

Service brake pedal (hydrostatic)/inching...................................................................................................................................................48

31

Tank – washer system................................................................................................................................................................................58

32

Control lever lock 11 for road travel............................................................................................................................................................ 46

33

Rotary switch – heating ..............................................................................................................................................................................57

30401b0010.iso

Printed in U.S.A.

Fig. 1:

Cab overview

34

918131/BP0207

Instrument panel overview: see overleaf

Instrument panel overview: see overleaf

Printed in U.S.A.

35

918131/BP0207

Instrument panel, multifunctional lever, drive lever: overview 5

34

35

36

37

38

39

40

41

42

43

Pos.

5

Description

For more information see page

Instrument panel

45

46

47

48

49

56

57

50

51

52

53

54

34

Indicator (green) – right/left turn indicator on rear attachment ............................................................................................................. 37, 56

35

Indicator (green) – right/left turn indicator ............................................................................................................................................ 37, 56

36

Indicator (red) – hydraulic oil filter .............................................................................................................................................................. 38

37

Indicator (red) – hydraulic oil temperature ................................................................................................................................................. 38

38

Indicator (red) – alternator charge function .......................................................................................................................................... 37, 43

39

Indicator (red) – parking brake ................................................................................................................................................................... 49

40

Indicator (red) – engine oil pressure .......................................................................................................................................................... 37

41

Indicator (yellow) – coolant temperature .................................................................................................................................................... 38

42

Indicator (green) – driving direction (forward/reverse) ............................................................................................................................... 50

43 44

Rocker switch – drive range selection (high/low) ....................................................................................................................................... 50 Not assigned

45

Fuel level indicator ..................................................................................................................................................................................... 38

46

Hour meter ................................................................................................................................................................................................. 37

47

Indicator (yellow) – 3rd control circuit, continuous operation ..................................................................................................................... 73

48

Indicator (blue) – high beam ................................................................................................................................................................ 37, 54

49 50

Switch – hazard warning system................................................................................................................................................................ 56 Socket/cigarette lighter

Control lever 51

Tip switch – neutral drive range ................................................................................................................................................................ 50

52

Toggle switch – drive direction selection (forward/reverse) ....................................................................................................................... 50

53

Tip switch – unlock 3rd control circuit (electric operation).......................................................................................................................... 73

54

Tip switch – lock 3rd control circuit (electric operation).............................................................................................................................. 73

Multifunctional lever 55

Not assigned

56

Rotary switch and tip switch – front/rear wiper, washer pump ............................................................................................................. 54, 56

57

Tip switch – horn ........................................................................................................................................................................................ 58

Switch panel

58

59

63

64

60

61

65

66 Fig. 1:

Printed in U.S.A.

62

67

15

58

Rocker switch – lights ................................................................................................................................................................................ 54

59

Rocker switch with lock – 3rd control circuit............................................................................................................................................... 72

60

Rocker switch with lock – 3rd control circuit (continuous operation).......................................................................................................... 72

61

Rocker switch – heater fan......................................................................................................................................................................... 57

62 63

Tip switch – rear window heating ............................................................................................................................................................... 57 Rocker switch – load stabilizer (option)

64

Rocker switch – working light (option)........................................................................................................................................................ 55

65

Rocker switch – rotating beacon (option)................................................................................................................................................... 55

66

Rocker switch with lock – 4th control circuit (option).................................................................................................................................. 78

67

Rocker switch – front socket for electrically operated implements (option) ............................................................................................... 76

68

Label – fuse box assignment ................................................................................................................................................................... 145

68

Instrument panel

36

918131/BP0207

Operation

Operation

Indicators and warning lights: overview Unfold page 36 for a better overview.

45 Indicator (green) – right/left turn indicator Flashes repeatedly when the turn indicators are used (lever 36/56).

46 Indicator (green) – right/left turn indicator on rear attachment Flashes repeatedly when the turn indicators (lever 36/56) are used and a front or rear attachment is connected electrically.

37 Indicator (red) – engine oil pressure Comes on if the engine oil pressure is too low. If the oil pressure is to low:

☞ Stop the machine. ☞ Turn off the engine immediately and check the oil level (➠ page 107).

Comes on after the ignition is turned on and turns off after the engine runs.

36 Indicator (red) – alternator charge function IMPORTANT! The coolant pump no longer runs if the V-belt is faulty. Danger of engine overheating or breakdown.

If indicator 36/38 comes on with the engine running:

☞ Turn off the engine immediately. ☞ Have the cause repaired by an authorized workshop.

The indicator comes on when the ignition is turned on and turns off as soon as the engine runs.

The V-belt for the alternator, or the charging circuit of the alternator is faulty if the indicator comes on with the engine running. The battery is not charged anymore (➠ page 112).

47 Indicator (blue) – high beam Comes on if high beam is turned on, or during headlight flashing.

39 Indicator (yellow) – cold starter Comes on when the key in start switch 36/60 is in position 2 (preheating).

A glow plug preheats the air in the combustion chamber of the engine when the key is in position 2.

43 Indicator (red) – parking brake

P

Comes on when parking brake lever 34/26 is applied.

The electric interlock prevents moving the machine with the parking brake applied.

44 Hour meter Counts the engine service hours with the engine running.

Printed in U.S.A.

37

918131/BP0207

Operation 35 Indicator (red) – hydraulic oil temperature Comes on if hydraulic oil temperature exceeds 203°F (95°C).

IMPORTANT! Danger of hydraulic damage as soon as indicator 36/37 comes on.

☞ Relieve work and maneuvering hydraulics. To do this: • Stop the machine.

• Move control lever 34/11 of the machine to neutral.

• Run the engine at increased speed until indicator 36/37 turns off.

34 Indicator (red) – hydraulic oil filter Indicates too high of pressure in the hydraulic reflux line to the tank. In this case:

☞ Have the hydraulic oil filter checked and, if necessary, replaced by an authorized dealer.

38 Indicator (red) – coolant temperature DANGER! Never open the radiator and never drain coolant if the engine is warm, because the cooling system is under high pressure –

Danger of burns. ☞ Wait at least 10 minutes after turning off the engine. ☞ Wear protective gloves and clothing. ☞ Open the cap to the first notch and allow the pressure to escape.

IMPORTANT! Danger of engine breakdown if indicator 36/41 comes on with the engine running. ☞ Stop engine immediately.

☞ Check and correct the coolant level (➠ page 110).

40 Fuel level indicator Indicates the fuel level in the fuel tank.

Printed in U.S.A.

38

918131/BP0207

Operation Getting started Safety instructions

• Never use the controls or cables as handles.

• Never climb onto or jump off a moving machine.

• Refer to the load diagrams for the loader unit pallet forks – see Load diagram on page 90.

Important information

• The machine may only be used in good operating condition in accordance with its designated use and the instructions set forth in the Operator’s Manual, and only by persons who are properly trained and fully aware of the risks involved in operating the machine – see Start-up checklist on page 40.

Running-in period

The performance and service life of the machine is heavily dependent on handling the machine carefully during its first 100 operating hours.

• Do not overload the machine.

• Do not run the engine at a high speed for extended periods of time.

• Increase the load gradually while varying the engine speed.

• Follow the maintenance schedule – see Maintenance schedule Model ML28 (overview) on page 131.

Printed in U.S.A.

39

918131/BP0207

Operation Start-up checklist

Use the checklists in this section to help you check and monitor the machine before, during and after operation.

Complete the checklist below before starting the engine or putting the machine into service: ✔

No. Question 1

Enough fuel in the tank? (➠ 105)

2

Coolant level OK? (➠ 110)

3

Engine oil level OK? (➠ 107)

4

Oil level in hydraulic tank OK? (➠ 115)

5

Water level in washer tank OK? (➠ 58)

6

V-belt condition and tension checked? (➠ 113)

7

Machine lubricated? (➠ 119)

8

Brake system (including parking brake) OK? (➠ 48)

9

Tire condition and inflation pressure OK? (➠ 122)

10

Wheel nuts tightened (especially after a wheel change)? (➠ 123, 148)

11

Lights, signals, indicators, warning lights and indicators OK? (➠ 54, 56, 37)

12 Windows, mirrors, lights and steps clean?

13 Control lever base folded down? (➠ 67) 14 Is the attachment on the machine correctly locked? (➠ 76) 15 Is the engine cover safely locked? (➠ 66) 16

Especially after cleaning, maintenance or repair work: Rags, tools and other loose objects removed?

17 Seat position and rearview mirror correctly adjusted? (➠ 43) 18 Seat belt fastened? (➠ 62)

Printed in U.S.A.

40

918131/BP0207

Operation Operation checklist

Complete the checklist below after starting the engine, during operation, and when driving on public roads: ✔

No. Question After starting and during operation: 1

Indicators for engine oil pressure, coolant level and alternator went out? (➠ 37)

2

Braking effect sufficient? (➠ 48)

3

Temperature indicator for engine coolant in normal range? (➠ 37)

4

Steering system working properly? (➠ 47)

5

Anyone hazardously close to the machine? (➠ 19)

When driving on public roads:

Parking checklist

6

Bucket and attachments in the transport position? (➠ 46)

7

Control lever for lift and tilt hydraulics of the machine locked with the lock? (➠ 47)

Complete the checklist below when parking the machine: ✔

No. Question When parking: 1

Attachments on the machine lowered to the ground? (➠ 51, 72)

2

Parking brake applied? (➠ 49)

3

Machine cab locked, especially if the machine cannot be supervised? (➠ 65)

When parking on public roads: 4

Machine adequately secured? (➠ 51)

When parking on uphill and downhill gradients: 5

Printed in U.S.A.

Machine additionally secured with chocks under the wheels to prevent it from rolling away? (➠ 51)

41

918131/BP0207

Operation Notes:

Printed in U.S.A.

42

918131/BP0207

Operation

Operation

Starting the engine ☞ Complete the Start-up checklist

Before starting the engine

– see Start-up checklist on page 40.

☞ Adjust seat position and rearview mirror.

CAUTION! All controls must be within easy reach. The operator must be able to fully move the brake and accelerator pedals.

☞ Fasten the seat belt. ☞ Make sure that the:

– Tip switch 36/51 is in neutral.

– Parking brake 34/26 is applied.

– The right-hand control lever base is folded down.

– Control lever 34/11 for operating the machine is in neutral.

General

• The engine will not start unless tip switch 36/51 is in neutral and parking brake 34/26 is applied.

• The starter cannot be operated if the engine is already running (start repeat interlock).

• Do not run the starter for more than 10 seconds.

• Wait for about one minute to let the battery recover before trying again.

NOTE: You cannot start the engine by towing the machine, because there is no driving connection between the engine and gearbox when the engine is turned off.

Starting the engine 38 39 40

After completing the instructions in Before starting the engine, above:

☞ Insert the ignition key in preheating start switch 34/15. ☞ Turn the ignition key to position “1”. ☞ Check whether the following indicators come on: • • •

36/40 for engine oil pressure.

36/38 for the alternator charge function.

36/39 if the parking brake is applied.

IMPORTANT!

Fig. 24: Indicators

If any of the above indicators DO NOT come on, they may be defective and should be replaced immediately.

☞ Turn the ignition key to position “2” and hold it in this position for about 5 seconds. ➥ The intake air is preheated. ☞ Press accelerator pedal 34/6 to about 25% of its maximum power. ☞ Turn the ignition key to position “3” and hold it in this position until the engine starts. ☞ Release the ignition key.

Printed in U.S.A.

43

918131/BP0207

Operation Starting the engine at low temperatures 38 39 40

☞ Turn the ignition key to position 2 and hold it in this position for about 15 to 20 seconds.

➥ The intake air is preheated. ☞ Press accelerator pedal 34/6 all the way down. ☞ Turn the ignition key to position “3” and hold it in this position until the engine starts. ☞ Release the ignition key.

When the engine runs smoothly (increased engine speed):

☞ Release accelerator pedal 34/6.

Fig. 26: Indicators

IMPORTANT! In general, a battery delivers less energy in cold conditions. Therefore make sure the battery is always well charged.

After the engine has started

☞ Check that the following indicators have gone out: • 36/38.

• 36/40.

☞ Let the engine warm up.

In cold (winter-type) weather:

☞ Increase the engine speed slowly. ☞ Do not run the engine at full load until it has reached its operating temperature.

Printed in U.S.A.

44

918131/BP0207

Operation Jump-starting the engine

Safety instructions DANGER! Never jump-start the engine if the battery is frozen, because there is a risk of explosion. The Model ML28 must not touch the jump-starting machine because when both machines are connected with jump leads, there is a risk of sparking.

• The external power source must deliver 12-V; higher supply voltages will damage the electrical systems of both machines.

• Use only authorized jumper cables that are in good condition.

IMPORTANT! The jumper cable connected to the positive (+) terminal of the starting battery must never touch electrically conductive machine parts, because there is a risk of short circuit.

• Route the jumper cables so that they cannot catch on rotating components in the engine.

Procedure ☞ Start the engine of the jump-starting machine.

☞ Connect one end of the red jump lead (+) to the + terminal of the dead battery, then connect the other end to the + terminal of the starting battery.

Dead battery

12 V

☞ Connect one end of the black jump lead (–) to the – terminal of the starting battery.

Connect the other end of the black jump lead (–) onto the engine block.

DANGER! DO NOT connect the other end to the negative terminal of the dead battery, because gas emerging from the battery may ignite if sparks are formed.

☞ Start the engine of the machine with the dead battery.

Once the engine has started:

☞ With the engine running, disconnect both jump leads in exactly the reverse order (first

12 V

remove the – terminal, then the + terminal) – this prevents sparking near the battery.

Starting battery Fig. 28: Starting aid with jump leads 34001b710_05.eps

Printed in U.S.A.

45

918131/BP0207

Operation Before driving the machine Special instructions for public roads

• Follow these instructions – see Use: attachment on page 9.

☞ Carry out a functional check of: • Brakes.

• Steering.

• Lights.

A

☞ Empty the bucket – see Hand lever of the machine on page 72.

B C

Ansicht_links.iso

Fig. 29: Driving on public roads

D

☞ Tilt back the bucket 29/B. ☞ Raise the wheel loader so that both red marks 30/D on the lift frame and the bulkhead are aligned.

IMPORTANT! Ground clearance for transport 29/C is about 8“ (200 mm) (with the standard bucket, standard tires, and both marks D aligned).

Fig. 29: Fig. 30: Marks for the transport position

Printed in U.S.A.

46

918131/BP0207

Operation Control lever lock (joystick)

A

11

The lock lever for locking the control lever is located on the lower left of the steering column near the brake pedal.

☞ Secure control lever 11 (joystick) for the machine and the attachments against unintentional operation. To do this:

32

B

Locking the lock lever ☞ Follow the instructions given – see Before driving the machine on page 46.

☞ Push lock lever 32/A down. ➥ The control valve is cut off from the hydraulic oil circuit.

Opening the lock lever Fig. 31: Lock for driving on public roads

Testing the steering system

☞ Push lock lever 32/B down. ➥ The control valve is connected to the hydraulic oil circuit. ☞ Functional check: Move the steering wheel to the left and right.

The power steering system is only operational when the engine is running. But if the diesel engine or hydraulic steering fails (e.g., failure of the pump drive), the machine can still be steered.

WARNING! If the power steering fails, turning the steering wheel requires greater effort.

Take this into account especially when towing the machine.

☞ Adapt towing speed to the steering. ☞ Use a towing bar.

Wheel synchronization position NOTE: The machine has self-synchronizing axles. Carefully steering the front and rear wheels to their limits automatically synchronizes the steering system of the machine.

If the wheels on both axles are not running in the same track:

☞ Drive at a low speed, turn the steering wheel slowly to the left and right maximum positions twice.

☞ Quickly turn the steering wheel back to the straight-ahead position. ➥ Make sure the wheels on the front and rear axles run in the same track. ☞ Contact your Mustang dealer if this does not synchronize the wheels.

Printed in U.S.A.

47

918131/BP0207

Operation Checking the service brake DANGER! Dirt on or around the brake pedal may prevent it from functioning correctly.

Accident risk. ☞ Always keep brake inching pedal 34/30 clean.

• The hydrostatic drive brakes the machine – see Brakes on page 143.

Service brake/inching pedal

Function • To brake the machine (regardless of the drive lever and accelerator pedal positions).

Braking

☞ Press brake inching pedal 34/30 down with force.

Inching

☞ Press brake inching pedal 34/30 down slightly.

• When you inch the pedal, it responds like a car’s clutch. The drive system is no longer supplied with hydraulic oil, which means that the entire engine output is available to the work hydraulics. This allows you to raise the boom more rapidly.

Printed in U.S.A.

48

918131/BP0207

Operation Parking Brake NOTE: You cannot start or move the machine unless parking brake 32/B is released.

Function • Prevents the machine from rolling away (use on sloped surfaces only).

• Emergency brake (only use if the service brake fails).

WARNING!

B

Only use parking brake 32/B instead of the service brake if the service brake fails. When you use parking brake 32/B, the brake lights do not light up, and the machine stops abruptly –

Accident risk.

Fig. 32: Parking Brake

Prevent rolling away A

WARNING! B

Using parking brake 33/B does not actuate neutral.

☞ Set the machine to neutral by pressing tip switch 36/51 on the joystick – see Select drive range on page 50.

Fig. 33: Applying and releasing the parking brake

☞ Pull lever B up into the top notch. ➥ Indicator 39 turns on.

Release the parking brake

☞ Carefully pull up lever 33/B. ☞ Press button 33/A. Move lever 33/B all the way down.

Printed in U.S.A.

49

918131/BP0207

Operation Select driving direction

F

CAUTION! Changing direction at high speed and full throttle causes the machine to brake immediately.

52

R

☞ Slow the machine to a walking pace before changing direction.

51

☞ Reduce engine speed by removing your foot from the accelerator pedal. ☞ Slow the machine to a walking pace. ☞ Select a new driving direction by using toggle switch 52 as follows:

42

Function Forward Reverse

Fig. 34: Select driving direction

Neutral

Operation ☞ Press toggle switch 52 forward F. ☞ Press toggle switch 52 backward R. ☞ Press tip switch 51.

Effect ➥ Indicator 42 (front arrow) comes on. ➥ Indicator 42 (rear arrow) comes on. ➥ Indicator 42 turns off.

Select drive range The machine has two (A/B) drive ranges. The drive range rocker switch is located on the instrument panel.

☞ Set driving direction to neutral by pressing tip switch 51 on the joystick. ☞ Select the required drive range with rocker switch 43. To do this: ☞ Press rocker switch 43/A. ➥ Drive range A is selected. ☞ Press rocker switch 43/B. ➥ Drive range B is selected.

52

Drive speed A

43

Symbol

Meaning

Recommended

Drive range A = 0 – 3.2 mph (0 – 5.1 k/mh).

Use for work involving short loading cycles, i.e., a rapid succession of loading and unloading operations (e.g., onto a truck), and for work requiring precise speed adjustment (e.g., rotary broom applications).

B Fig. 35:

Select drive range

Printed in U.S.A.

Drive range B = 0 – 12.4 mph Use for long-haul travel.

(0 – 20 k/mh).

50

918131/BP0207

Operation Parking the machine WARNING! Machines parked on slopes may roll away:

☞ Use the parking brake – see Parking Brake on page 49.

☞ Place chocks under the downhill sides of the wheels.

11 52

Proceed as follows: ☞ Reduce engine speed by removing your foot from the accelerator pedal 34/6.

☞ Stop the machine by pressing service brake 34/30. ☞ Set the driving direction to neutral by using tip switch 36/52. ☞ Use the parking brake – see Parking Brake on page 49. ➥ Indicator 36/39 in the instrument panel comes on. ☞ Lower the machine: • Push control lever 11 forward out of neutral.

Fig. 36: Tip switch for neutral position

• Push control lever 11 to the left or right to place the bucket on the ground so that the edge is flat with the ground – see Hand lever of the machine on page 72.

After operation at full power:

☞ Allow the engine to run until the temperature stabilizes: ☞ Turn off the engine: • Turn the ignition key to position “0”.

• Remove the ignition key.

Parking on sloped surfaces:

☞ Secure the machine by placing chocks under the downhill sides of the tires.

Differential lock IMPORTANT! A differential lock distributes traction evenly to the front and rear wheels.

Both the front and rear axles of the machine are fitted with self-locking differentials. The lock value is 45% for each axle. The differential is locked automatically and cannot be turned on or off by the operator.

Printed in U.S.A.

51

918131/BP0207

Operation Load stabilizer (option) The load stabilizer protects the machine against unstable oscillating movements.

WARNING! When driving on public roads, the machine may become unstable if the load stabilizer is NOT turned on –

Accident risk. ☞ Always turn on the load stabilizer when driving on public roads. ☞ Follow the procedure described – see Before driving the machine on page 46, when setting the transport position.

IMPORTANT! DO NOT use the load stabilizer while performing heavy duty work.

Refer to the following table to determine when to use the load stabilizer: Load stabilizer Turned off Turned on • In general for heavy-duty • For driving on public work, e.g., picking up roads. excavated material.

May be turned on • For lighter work with the machine.

• For light off-road transport.

Before working with the loader unit

☞ Turn off the load stabilizer.

IMPORTANT! The loader unit yields easily with the load stabilizer turned on, making it difficult to carry out any precise lifting movements. The lifting capacity of the machine is only about 60% of the rated capacity.

Turning on 63 Fig. 37: Rocker switch for load stabilizer (option)

Printed in U.S.A.

A B

☞ Press bottom of rocker switch 63, below A. ➥ Indicator in rocker switch comes on.

Turning off

☞ Press top of rocker switch 63, above B. ➥ Indicator in rocker switch turns off.

52

918131/BP0207

Operation Backup warning system The backup warning system consists of a backup alarm A fitted to the inside of lid B, and a switch and wiring. The backup alarm generates an acoustic signal when you shift into reverse. The acoustic level is about 103 dB(A) at a distance of 3’ (1 m) and at a frequency of ML280 Hz. WARNING! B A Fig. 38: Backup warning system

Printed in U.S.A.

When backing up with the machine –

Accident risk. ☞ Make sure nobody is within the work area of danger of the machine. ☞ Do not rely exclusively on the backup alarm to alert others.

53

918131/BP0207

Operation Light system Parking lights/low beam 58

A B

Fig. 39: Light system switches

The switch panel for the light system is located behind the joystick in the control lever base.

Parking lights ☞ Press rocker switch 58/B to the ON 1st position. ☞ Press rocker switch 58/A down.

OFF Low beam ☞ Press rocker switch 58/B to the ON 2nd position. ☞ Press rocker switch 58/A down.

OFF

➥ Indicator in rocker switch 58 comes on.

➥ Indicator in rocker switch 58 turns off.

➥ Indicator in rocker switch 58 comes on.

➥ Indicator in rocker switch 58 turns off.

IMPORTANT! The parking light stays lit if the ignition is turned off. Turn off the parking light by turning the key in preheating start switch 34/15 to position 0.

High beam/headlight flasher

48

47

56

High beam ☞ With low beam turned on, pull lever 56 to position II (toward ON the steering wheel) and release. ☞ Pull lever 56 to position II (toward the steering wheel) OFF and release.

Headlight flasher ☞ Pull lever 56 upward to ON position I and hold.

II

➥ High beam turns on. ➥ Indicators 47, 48 turn on. ➥ Low beam turns on. ➥ Indicators 47, 48 turn off.

➥ High beam and indicators 47, 48 come on.

I O

Fig. 40: Right-hand side steering column control lever

Printed in U.S.A.

54

918131/BP0207

Operation Working light (option) WARNING! The working light may momentarily blind motorists on public roads.

☞ DO NOT turn on the working light when driving on public roads.

Front and/or rear working lights (option) ☞ Press rocker switch 64/B down.

ON OFF

☞ Press rocker switch 64/A down.

➥ Indicator in rocker switch 64 comes on.

➥ Indicator in rocker switch 64 turns off.

A B 64 Fig. 41: Switch for working light

Rotating beacon (option) Rotating beacon (option) ☞ Press rocker switch 65/B. ON OFF

☞ Press rocker switch 65/A.

➥ Indicator in rocker switch 65 comes on.

➥ Indicator in rocker switch 65 turns off.

C

65

A B

Fig. 42: Switch for rotating beacon

Printed in U.S.A.

55

918131/BP0207

Operation Interior light Interior light ☞ Press switch 2 to the left or right.

ON OFF ☞ Move switch 2 to center position.

2 Fig. 43: Switch for interior light

Signaling system Hazard warning system 34

Hazard warning system ☞ Press switch for hazard warning ➥ The indicator in switch 36/49 flashes.

ON system 36/49 to notched position. ☞ Release switch for hazard warning ➥ The indicator in switch 36/49 turns off. system 36/49 from notched posiOFF tion by applying slight pressure.

49

Fig. 44: Switch for hazard warning system

Turn indicator

56

L

Turn indicator ☞ Push lever 56 forwards L. LEFT

➥ Indicator

☞ Pull lever 56 to the rear R.

➥ Indicator

RIGHT

36/34 flashes.

36/34 flashes.

R Fig. 45: Turn indicator

IMPORTANT! If indicator 36/34 flashes about twice as fast as normally.

☞ Check the front and rear indicators immediately. ➥ Have the turn indicator system repaired if necessary.

Printed in U.S.A.

56

918131/BP0207

Operation Cab heating and ventilation 5 NOTE: The machine heater can be set to two modes: • Ventilation.

• Heating.

The air flow is directed to the front window via two defroster nozzles 5 and to the cab via footwell nozzle 10.

I 0

Each nozzle can be closed and directed separately.

10 Fig. 46: Air circulation in cab

A B

61

Ventilation (fresh air) ☞ Press rocker switch 61/A once.

1st speed ☞ Press rocker switch 61/A twice.

2nd speed ☞ Press rocker switch 61/A three times.

OFF

➥ Fan runs in 1st speed. ➥ Fan runs in 2nd speed. ➥ Fan OFF.

Fig. 47: Fan switch

Heating

33 A

Colder Warmer

☞ Turn switch 33 to B. ☞ Turn switch 33 to A.

B

Fig. 48: Heating adjustment

Rear window heater 62

B

Fig. 49: Rocker switch – rear window heating

The rear window heater prevents the rear window from fogging.

☞ Press rocker switch 62/B. ➥ Indicator in rocker switch 62 comes on.

• The rear window heating turns off automatically after about 5 minutes. ➥ Indicator in rocker switch 62 turns off.

NOTE: The rear window heater can only be active if the engine is running.

Printed in U.S.A.

57

918131/BP0207

Operation Windshield washer system

ON ON OFF

56

Front and rear window wiper ☞ Turn rotary switch 56 once . ☞ Turn rotary 56 switch twice .

☞ Turn rotary 56 switch rearward twice.

➥ Front wiper is on. ➥ Front and rear wipers are on. ➥ Front and rear wipers return to starting position.

Fig. 50: Switch for front and rear wipers

A

B

Washer pump for front and rear window ☞ Press rotary switch 56 to the left (A) and hold.

ON OFF

☞ Release rotary switch 56 (B).

56 Fig. 51: Washer pump

Tank for windshield washer system The filler inlet for the windshield washer system (tank 31) is located at the lower left corner of the cabin, near the brake pedal.

IMPORTANT!

31

Fill with clean tap water only. Add a suitable cleaning agent if required. In winter, add antifreeze for washer systems to the water – see Specific safety instructions on page 109.

Fig. 52: Tank for washer system

Printed in U.S.A.

58

918131/BP0207

Operation Notes:

Printed in U.S.A.

59

918131/BP0207

Operation Operator's seat Seat adjustment 22

23

27 307b0370.ai

25

Fig. 53: Seat adjustment

307b0380.ai

WARNING! Never change the seat position when driving or working –

Accident risk.

Weight setting IMPORTANT! Use lever 23 to adjust the seat suspension to the operator's weight in 9 levels 110 – 287 lbs. (50 – 130 kg).

☞ Sit down on the operator’s seat.

To adjust to a higher operator weight:

☞ Press lever 23 down (22 lbs.[10 kg] per notch).

To adjust to a lower operator weight: 23 307b0360.ai

☞ Press lever 23 down against the lower limit. ➥ Weight setting automatically returns to the upper 110 lbs. (50 kg) position. ☞ Press lever 23 down to the required position.

Fig. 54: Weight setting

Printed in U.S.A.

60

918131/BP0207

Operation Horizontal adjustment

☞ Sit down on the operator’s seat. ☞ Pull lever 25 upward A and at the same time move the operator's seat forward or

B

rearward.

A

25

307b0330.ai

Fig. 55: Horizontal seat adjustment

Backrest adjustment E

☞ Sit down on the operator’s seat. ☞ Pull handle 27 up B – and at the same time move the seat forward or rearward. The backrest reclines as follows:

D

• Seat moved forward.

• Seat moved rearward.

27 B

➥ Flatter backrest inclination. ➥ Steeper backrest inclination.

307b0350.ai

Fig. 56: Backrest adjustment

Printed in U.S.A.

61

918131/BP0207

Operation Seat belt WARNING! Do not drive or work with the seat belt unbuckled –

Risk of personal injury. ☞ Buckle up before moving or working with the machine.

• Seat belt must not be twisted.

• Seat belt must run over the hips – not over stomach – and must always be applied tightly.

• Do not place seat belt over hard-edged or fragile items (tools, metal ruler, glasses, pen) carried inside your clothes.

• Never buckle up two persons with one seat belt.

• Check seat belts regularly. Have damaged parts immediately replaced by an authorized dealer.

• Always keep the seat belt clean.

• Seat belt buckle must not be obstructed by other objects (paper or similar); otherwise the buckle latch cannot lock into place.

After an accident, the seat belt strap is stretched and must be replaced. In another accident the same strap –

Will not provide adequate protection. ☞ Replace the seat belt strap after an accident. ☞ Have fastening points and seat fixture checked for bearing capacity.

Seat belt 24 is for the operator's safety during work on construction sites and during road travel.

Fastening the seat belt Fasten seat belt 24 as follows before moving the machine: ☞ Hold the belt at buckle latch A and run it slowly and steadily over the hips to buckle B. A 24

☞ Insert buckle latch A into buckle B until it engages audibly (pull test). ☞ Tighten the seat belt by pulling at its end. ➥ The seat belt must always be tightly in place over the hips.

B

0763b0007.eps Fig. 57: Fastening the seat belt

Printed in U.S.A.

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Operation Unfastening the seat belt Unfasten seat belt 24 as follows:

24 A

☞ Hold the seat belt. ☞ Press red button C on buckle B. ➥ Latch A is released from buckle B by spring action. ➥ Slowly return the seat belt to the retractor.

C B 30763b0006.eps Fig. 58: Unfastening the seat belt

Lengthen/shorten seat belt setting

☞ Lengthen the seat belt as follows:

A

• Hold buckle latch A at a right angle to the seat belt and pull the seat belt to the required length – see Fig. 59.

☞ Shorten the seat belt by pulling the free end D of the belt – see Fig. 59.

IMPORTANT!

D

30763b0005.eps Fig. 59: Lengthen/shorten seat belt setting

Printed in U.S.A.

The automatic seat belt allows free and easy movement when pulled slowly, but locks during abrupt braking. The automatic seat belt may also lock when driving over potholes or uneven terrain.

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Operation Doors and side windows WARNING! Close the doors and the side windows when driving and working with the machine –

Accident risk ☞ Close the doors before moving the machine. ☞ Lock the side windows – see Side windows on page 65.

Door (left/right) Opening the door from the outside

☞ Press door lock A. Locking the door

☞ Turn the key in door lock A to the right.

A

Unlocking the door Turn the key in door lock A to the left.

Fig. 60:

Outside door opener and lock

L

Opening the door from the inside

☞ Pull door lock lever B upward on the inside left or right.

NOTE:

B

Normally, enter and exit the cab by using the left door.

– see Folding back the control lever base on page 67.

Fig. 61: Inside door opener left/right

Printed in U.S.A.

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Operation

Side windows Locking and unlocking the side windows

☞ Turn lever C downward. ➥ Side window locked. ☞ Turn lever C upward. ➥ Side window unlocked.

C

Fig. 62: Locking and unlocking the side windows

Opening the hinged side windows

B

☞ Turn lever C upward. ☞ Slide lever C outward horizontally. ☞ To fasten the window in its final position:

Press the end of lever A downward in guide B.

A

C Fig. 63: Opening the hinged side windows

Fully opening the side windows

☞ Turn lever C upward. ☞ Slide lever C outward horizontally. ☞ In order to completely swing the window outward:

Pull the end of lever A to the inside (to the operator) out of guide B.

C

A

B

Fig. 64: Opening the hinged side windows

Securing open side windows 12

20

☞ Press the side window against arrester 20 of lock 12 until it locks with an audible click.

IMPORTANT! Lubricate the arrester 20 at least every 500 service hours.

Fig. 65: Securing an open door

Printed in U.S.A.

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Operation

12

D

Unlocking the side windows

☞ Press button D of door arrester 12 and slightly pull the side window.

Fig. 66: Unlocking the door arrester

Engine cover Opening:

A

☞ Press lock A. ☞ Pull the engine cover upward.

Closing:

☞ Firmly press down the engine cover until lock A engages with an audible click.

L R

Locking and unlocking: Close the engine cover with the ignition key of the ignition switch. ☞ Turn the ignition key in lock A to the left (L).

➥ Engine cover locked.

Fig. 67: Engine cover lock

Printed in U.S.A.

☞ Turn the ignition key in lock A to the right (R). ➥ Engine cover unlocked.

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Operation Other controls Folding back the control lever base The cab door on the right can be used as entry and exit.

☞ Do the following before entering or leaving the cab: • Stop and secure the machine – see Parking the machine on page 51.

• Lower the machine.

11 14

• Apply the parking brake.

• Turn off the engine.

• Remove the ignition key.

• Move control lever 11 (joystick) back and forth several times – see Lowering the loader unit with the engine turned off on page 74.

☞ Raise control lever base 14 with handle D to position A. ➥ The gas strut keeps the control lever base in the top position.

CAUTION!

D

Do not use handle D on the control lever base as a support for your entrance or exit:

14

A

B Fig. 68: Control lever base

Printed in U.S.A.

C

☞ Use the entrance handles in the cab. ☞ Fold control lever base 14 down to position B once you are in the cab. ➥ The gas strut keeps the control lever base in the lower position.

NOTE: Use stop bolt C to set the control lever base height.

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Operation Removing the cab for low clearance heights Machine height without cab – see Dimensions on page 150.

A

WARNING! Incorrectly removing the cab with a crane –

Accident risk.

B

☞ Have loads fastened. ☞ Make sure the lifting capacities of the crane and the lifting gear (cables, chains) are sufficient.

☞ Avoid suspended loads. ☞ Always read the safety instructions – see Safety instructions on page 15.

☞ Remove the cab as follows: • Drive the machine onto level ground.

C D

• Turn off the engine.

• Remove the ignition key.

• Lower the loader unit without pressure – see Lowering the loader unit with the engine turned off on page 74.

• Break electric contact A (behind the operator's seat, on the right).

• Remove the fixtures for headlights B on the left and right of the machine frame.

• Unscrew hexagon head screws C for the attachment of the cab on the left and right.

• Carefully raise the cab at the four eye hooks D by using a crane.

• Place the cab onto level ground.

34001b330_01.eps

Fig. 69: Removing the cab

Mounting the cab

☞ Mount the cab in the reverse order of removal.

• Tightening torque for cab attachment: 144 lb.-ft. (195 Nm).

Printed in U.S.A.

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Operation ROPS bar (option) Important safety information DANGER! Do not drive or work with the ROPS bar folded down –

Risk of personal injury. ☞ Always fold up and lock the ROPS bar during normal operation. ☞ Never use a wheel machine fitted with ROPS bar in the area of falling objects.

Folding down the ROPS bar Removing lock pins A.

A

2

☞ Hold the ROPS bar. ➥ A gas strut holds the ROPS bar in its position by applying slight pressure. ☞ Release and remove lock pins A on the left and right. ☞ Fold back the ROPS bar. ➥ Position 1 For opening the engine cover. ➥ Position 2 Clearance height – max. 78” (1985 mm). ☞ Mount the lock pins A in the required positions and secure them with hinged split pins.

1

Fig. 70: Folding down the ROPS bar

Printed in U.S.A.

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Operation Notes:

Printed in U.S.A.

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Operation

Operation Working with the machine General safety instructions

• Never drive up to the edge of a pit from the outside – danger of cave-in.

• Never undermine the foundations of walls – danger of collapse.

• When excavating, look out for high-voltage and underground cables, and gas and water pipes.

• When using lifting accessories such as pallet forks, comply with the load diagrams – see Load diagram on page 90.

• The hydraulic system of the machine is still pressurized even when the engine is not running. Depressurize the sections of the system and hydraulic lines that you want to open before starting setup or repair work (e.g., fitting/removing an attachment with hydraulic functions) – see Depressurizing the quick couplers on the loader unit on page 74.

• If your machine is equipped with a load stabilizer (option): IMPORTANT! Turn off the load stabilizer before working with the loader unit. If you leave the load stabilizer on, the lifting capacity of the machine is only about 60% of the rated force, and it is difficult to complete precise lifting movements.

Printed in U.S.A.

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Operation Hand lever of the machine Control lever for lift and tilt cylinder hydraulics

WARNING! Unintentional operation of control lever 11 when driving on public roads:

Accident risk. ☞ Lock the lock lever – see Control lever lock (joystick) on page 47.

E 11

C A

B D

Position A B C D E

Lever 11 ☞ Left ☞ Right ☞ Forward ☞ Rearward ☞ Fully forward

Function ➥ Tilts in attachment ➥ Dumps out attachment ➥ Lowers boom ➥ Raises boom ➥ Lowers boom to float position (option)

NOTE: The control valve is equipped with a float position. This helps you when working with a rotary broom, snowplow, and grading in reverse.

Fig. 71: Control lever for machine

Complete the following procedures to turn on the float position: ☞ Push control lever 11 fully forward to final position E.

➥ Control lever stays in final position E. Operation of 3rd control circuit 54

53

WARNING! When working with attachments without a hydraulic function, press tip switch 53 on the control lever 11 to unlock the quickhitch facility –

Risk of personal injury. ☞ Turn off rocker switch 59 – see Locking 3rd control circuit on page 72.

☞ Use rocker switch 59 to lock the 3rd control circuit as follows:

11 C 59

Locking 3rd control circuit ☞ Push lock C down ON

A

☞ At the same time press rocker

Function ➥ Indicator in rocker switch 59 comes on.

switch 59 down to position B.

➥ Tip switches 53 and 54 are ready for

☞ Press rocker switch 59 down to

➥ Indicator in rocker switch 59 turns off. ➥ Rocker switch 59 is locked. ➥ Tip switches 53 and 54 do not

operation.

B OFF

position A.

function.

Fig. 72: Locking 3rd control circuit

Printed in U.S.A.

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Operation ☞ The 3rd control circuit is actuated by using tip switches 53 and 54, with rocker 53

switch 59 /B turned on

54

– see Locking 3rd control circuit on page 72.

Operation of 3rd control circuit

Function

➥ With the quickhitch facility connected: ➥ With an attachment connected:

Locking: ☞ Press tip switch 54.

➥ With an attachment connected:

11 C

59

59 A B

• Unlocks the quickhitch facility.

Unlocking: ☞ Press tip switch 53.

Continuous setting: ☞ Push lock C down ☞ At the same time press rocker switch 60 down to position B.

• Pressurizes the right-hand side hydraulic line (blue) (e.g., closes multipurpose bucket). ➥ With the quickhitch facility connected: • Locks the quickhitch facility.

• Pressurizes the left-hand side hydraulic line (red) (e.g., opens multipurpose bucket). ➥ Indicator in rocker switch 60 comes on.

➥ Indicator 47 on the instrument panel comes on.

• Hydraulic movements/procedures over a longer period of time or operation of hydraulic motors.

• Operation of hydraulic equipment with a control valve adjusted to maximum oil flow, with an unpressurized reflux.

Fig. 73: Operation of 3rd control circuit

Printed in U.S.A.

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Operation Lowering the loader unit with the engine turned off Lower the machine as follows: C

11

☞ Make sure no one is near the machine. ☞ Push and hold control lever 11 forward (C). ➥ Until the machine is completely lowered. ☞ Return control lever 11 to neutral.

Fig. 74: Lowering the loader unit with the engine turned off

Depressurizing the quick couplers on the loader unit IMPORTANT! The hydraulic system of the machine is still pressurized even when the engine is not running. The hydraulic quick couplers can be released, but they cannot be re-attached because the hydraulic lines are not depressurized.

☞ Depressurize sections of the system and hydraulic lines that you want to open before starting setup or repair work, (e.g., fitting/removing an attachment).

Depressurize as follows:

☞ Apply the parking brake

11

– see Parking Brake on page 49.

53

54

☞ Turn off the engine. ➥ Do not turn off the ignition. ☞ Press and hold tip switches 53 and 54 on control lever 11 for about 5 – 8 seconds. ➥ Hydraulic lines are depressurized. ☞ Turn off the ignition and remove the ignition key. ☞ Re-installing the attachments.

Re-installing the attachments is described on the next page for the standard bucket. If you are fitting or removing attachments with their own hydraulic functions you must follow the special information given in the attachment's Operator’s Manual.

Fig. 75: Releasing pressure on the quickhitch facility

Printed in U.S.A.

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Operation Re-installing the attachments ac

Re-installing the attachments is described below for the standard bucket. If you are fitting or removing attachments with their own hydraulic functions (e.g. high-tilt or side dump bucket) you must follow the information provided in the Operator’s Manual of the attachment.

Fitting attachments onto the quickhitch facility

WARNING! The attachment must always be safely locked onto the quickhitch facility –

Accident risk. ☞ Before working, be sure that the attachment is locked onto the quickhitch by

using the lock cylinder. Be sure that you can see the lock pins on both sides of the mounting holes on the attachment.

Re-install as follows: 11

☞ Drive the machine up to the attachment. ☞ Tilt the quickhitch facility all the way forward by pushing control lever 11 to the right B. ☞ Adjust the height of pin shanks L of the quickhitch facility so that they are under the

C B

catch hooks of attachment K. To to this:

D

Lift frame • Lower • Raise

Control lever 11 ☞ Push forward C. ☞ Pull rearward D.

☞ Drive the machine forward until pin shanks L of the quickhitch facility are directly

K

beneath the catch hooks of attachment K.

L Fig. 76: Driving up to the attachment

☞ Raise loader unit G. To do this: C

Pull control lever 11 rearward D.

11

☞ Fully tilt in quickhitch facility H. To do this: Push control lever 11 to the left A.

A D

H G Fig. 77: Raising the attachment

Printed in U.S.A.

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Operation Locking: Attachments without hydraulic function 53

Secure the attachment with lock pin G of the quickhitch facility. To do this:

54

☞ Press tip switch 36/54 on control lever 11. ➥ Lock pin G engages in the mounting holes of the attachment. ➥ Make sure the attachment is safely locked with lock pins G. ☞ Release tip switch 36/54 on control lever 11. ☞ Lock the 3rd control circuit with rocker switch 59/A:

11 59

– see Locking 3rd control circuit on page 72 (OFF).

A B

WARNING! You must be able to see lock pins G on the left and right of the mounting holes on the attachment. The attachment is not safely locked unless you can see the lock pins.

Attachments with hydraulic function

G

☞ Turn off the engine. ➥ Do not turn off the ignition. ☞ Apply the parking brake. ☞ Unlock the 3rd control circuit with rocker switch 59/B:

Fig. 78: Locking the attachment

– see Locking 3rd control circuit on page 72 (ON).

☞ Depressurize the 3rd control circuit:

– see Depressurizing the quick couplers on the loader unit on page 74.

☞ Attach the hydraulic and electrical connections (if used) for the attachment by following its Operator’s Manual.

Connection of electrically operated attachments (option) The machine can be fitted with a 4-pole front and/or rear socket. Rocker switch 67 turns electric power supply on or off for electrically operated attachments (such as a spray water pump for a rotary broom).

A B

67 Fig. 79: Switch for attachments (option)

Printed in U.S.A.

Power supply for front attachments (option) ☞ Press rocker switch 67 down ➥ Power supply at the front socket is to position B turned on ON ➥ Indicator in switch comes on ☞ Press rocker switch 67 down ➥ Power supply is interrupted OFF to position A ➥ Indicator turns off

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Operation Removing an attachment from the quickhitch facility

WARNING! The attachment must be placed on the ground so that it will not fall over when removed –

Risk of personal injury. ☞ Position the attachment so that after unlocking it will not tip over.

Take the attachment off the quickhitch facility as follows:

☞ Be sure that the attachment is empty and up. ☞ Tilt in quickhitch facility H by pushing control lever 11 to the left A. ☞ Lower G until the attachment is about 2–4” (5–10 cm) above the ground by pushing

C A

11

control lever 11 forward C.

D

☞ Unlock the 3rd control circuit by using rocker switch 59:

59

– see Locking 3rd control circuit on page 72 (ON).

For attachments with hydraulic function

☞ Turn off the engine. ➥ Do not turn off the ignition. ☞ Unlock the 3rd control circuit with rocker switch 59 (ON): H

G

– see Locking 3rd control circuit on page 72.

☞ Depressurize the hydraulic lines: – see Depressurizing the quick couplers on the loader unit on page 74.

☞ Hydraulic connection (on the lock cylinder): Follow the attachment's Operator’s Manual, for hydraulic connections to the machine.

Fig. 80: Lowering and tilting in the attachment

53

Open the lock on the quickhitch facility. To do this:

54

C

☞ Press tip switch 36/53 on control lever 11. ☞ Slightly tilt the quickhitch facility forward H. To do this:

B

Push control lever 11 to the right B.

☞ Lower G. To do this:

Push control lever 11 forward C.

11

As soon as pin shanks L of the quickhitch facility are beneath the catch hooks of attachment K:

☞ Reverse the machine away from the attachment.

K

H

G

L Fig. 81: Taking off the attachment

Printed in U.S.A.

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Operation High flow front control circuit WARNING! When working with attachments without hydraulic function: Pressing tip switch (fig. 83) 53 on control lever 11(joystick) unlocks the quickhitch facility –

Risk of personal injury. ☞ Press rocker switch 59 (fig. 83) in position A to lock.

C

– see Locking 3rd control circuit on page 72 –

For operation of hydraulically operated front attachments (e.g. rotary broom) or hydraulically operated rear attachments (e.g. salt sprayer), the machine must be equipped with a high flow front/rear control circuit (option).

D

E

IMPORTANT! The load is reduced if hydraulic attachments are connected at the front and rear at the same time.

F

☞ See the Operator’s Manual of the attachment manufacturers for installing and operating the attachments.

Fig. 82: Front and rear hydraulic connections (option)

Front/rear hydraulic connections (option) Connection C

Color Blue

Function Unpressurized reflux to tank

D

Red

Pressure line

E

Red

Unpressurized reflux to tank

F

Red

Pressure line

Operation: 53

☞ With rocker switches 66. ➥ 14 gal/min (52 l/min) (front and rear connections). ☞ additionally with rocker switch 60. ➥ 20 gal/min (75 l/min) (front connection only): the 4th control circuit is turned on or off

54

with a solenoid valve.

11 60

C

66 A B A B

Fig. 83: Operation of 4th control circuit

Printed in U.S.A.

Operation of 4th front/rear control circuit (option) ☞ Push lock C down. ➥ 4th control circuit is turned on.

ON ☞ Press rocker switch 36/66 ➥ Indicator comes on. down to position B. ☞ Press rocker switch 36/66 to ➥ 4th control circuit is turned off.

OFF position A. ➥ Indicator turns off.

Specifications: – see Additional high flow control circuit (option) on page 144.

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Operation Hose burst valve safety feature (option) IMPORTANT! If a hose or line bursts, the hose burst valve prevents the boom from being lowered or dumped out without being braked – see Applications with lifting gear on page 18.

WARNING! Hose burst valve activates when a hose or a line bursts –

Accident risk. ☞ Have any hydraulic system and hose burst valve damage immediately checked and repaired by technical staff with training.

If there is damage, follow these instructions:

☞ Stop the machine. ☞ If possible: • Carefully lower the boom into the transport position.

• Drive the machine out of the area of danger with the boom lowered.

☞ Apply the parking brake. ☞ Turn off the engine. ☞ Remove the ignition key and lock the cab. ☞ Secure both the machine and the attachment.

Environment! ☞ Collect and dispose of drained hydraulic oil in accordance with environmental laws.

☞ Have the hose burst valve immediately repaired by an authorized dealer.

Printed in U.S.A.

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Operation Working with the standard bucket This section describes work operations for the machine equipped with the standard bucket.

The standard bucket is mainly used for digging, loosening, lifting, transporting and loading loose or solid materials.

Checking the tilt position of the bucket A

IMPORTANT! Angle of mark A = angle of blade B. B

Fig. 84: Tilt position of the bucket

Checking the transport position of the bucket

IMPORTANT!

A

The bucket is in the transport position if: • Bucket is tilted in completely A.

B Fig. 85: The transport position of the bucket

• Marks on the loader unit and the machine frame are lined up 86/C. The distance of the bucket (with standard tires) to the ground B is about 8” (20 cm).

C

Fig. 86: Marks on boom and machine frame

Printed in U.S.A.

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Operation Transporting with a full bucket

WARNING! Transporting full buckets in the raised position is an –

A

Accident risk.

Pay attention to this when cornering or driving on slopes. The lower the bucket and center of gravity, the less risk there is of tipping over.

B Fig. 87: The transport position of the bucket

To avoid accidents:

☞ Tilt the bucket fully in. ☞ Raise the bucket to the transport position – see Fig. 87. ☞ Tilt the bucket all the way in A. ☞ Raise the bucket to the transport position. ➥ Fig. 87/B and 88/C.

C

Fig. 88: Marks on loader unit and frame

Loading loose material

☞ Align the blade parallel with the ground A C

11

– see Checking the tilt position of the bucket on page 80.

☞ Lower the bucket to the ground B. To do this: Push control lever 11 forward C.

B A Fig. 89: Lowering of the loader unit

☞ Drive forward into the material A.

11

When the engine speed decreases due to too much material: D

☞ Slightly raise the bucket B. To do this: Pull control lever 11 rearward D.

B A

Fig. 90: Driving into the material

Printed in U.S.A.

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Operation Loading if the material is hard to penetrate A

B

☞ Proceed as for loading loose material. ☞ Tilt the bucket in and out slightly by moving control lever 11 to the left and right A and B.

11

Fig. 91: Loading if the material is hard to penetrate

Ending loading A 11

☞ Tilt in the bucket C by pushing control lever 11 to the left A. ☞ Reduce engine speed.

C

Fig. 92: Tilting in the bucket

☞ Reverse out of the material A. ☞ Raise the bucket to the transport position B. A B Fig. 93: Reversing out of the material

Printed in U.S.A.

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Operation Removing material/digging in soft soil 11

C

WARNING! If foundations or walls are undermined – danger of collapse.

Accident risk.

B

☞ Never undermine foundations or walls.

Fig. 94: Lowering the bucket horizontal to the ground

11

B

☞ Place the bucket horizontally on the ground B by pushing control lever 11 forward C. ☞ Set the digging angle α 1 by pushing control lever 11 to the right B.

1

α

1 Fig. 95: Setting the digging angle

☞ Drive the machine forward 1.

A

After the bucket has penetrated the soil:

11

☞ Set the digging angle α slightly flatter 2 by pushing control lever 11 to the left A, so that the: • Layer being removed is as even as possible.

1

• Wheel spin is reduced.

2

☞ Proceed as for loading loose material.

Fig. 96: Removing an even layer

Printed in U.S.A.

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Operation Digging in hard soil

☞ Lower the bucket horizontally to the ground 1 by pushing control lever 11 forward C. ☞ Set the digging angle α (flatter) 2 by pushing control lever 11 to the left A. ☞ Drive the machine forward 3. ☞ Press the bucket down slightly by pushing control lever 11 forward C.

C 11

A

3 1

2 Fig. 97: Removing hard soil

A

11

B

After the bucket has penetrated the soil:

☞ Set the digging angle α slightly flatter 1 by pushing control lever 11 to the left A, so that the: • Layer being removed is as even as possible.

• Wheel spin is reduced.

☞ Push control lever 11 to the left A, or move it alternately to the left and right A and B to loosen the material.

1

☞ Proceed as for loading material hard to penetrate.

Fig. 98: Setting the digging angle flatter

Loading heaped material (non-compacted material) WARNING! Digging under heaped material can cause it to collapse –

Accident risk. ☞ Never undermine heaped material. ☞ Set the blade parallel to the ground by pushing control lever 11 to the left or right A and B.

C A

11

B

☞ Lower the bucket horizontally to the ground by pushing control lever 11 forward C.

☞ Drive forward.

After penetrating the heaped material: ☞ Smoothly raise the boom.

☞ Keep the bucket level.

Fig. 99: Penetrating heaped material

When the boom cannot be raised further: ☞ Tilt in the bucket 1.

1

3

☞ Raise the boom 2. ☞ Reverse out of the material 3. ☞ Lower the loader unit into the transport position.

2 Fig. 100: Reversing away from heaped material

Printed in U.S.A.

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Operation Loading heaped material (compacted material) A

B

11

☞ Proceed as for non-compacted material. ☞ When raising the boom through the heaped material: tilt the bucket slightly in and out 1. ☞ To do this: move control lever 11 alternately to the left and right (A and B). ➥ Material is loosened.

1 Fig. 101: Heaped compacted material

Grading After having finished removing/loading the material:

☞ Lower the bucket horizontally to the ground 1. ☞ Reverse across the surface to be graded 2.

2

1

Fig. 102: Grading

Digging tips While digging, we recommend the following: • Exit the pit, as level as possible, from outside the digging line.

• Dig by removing adjacent strips.

• Make sure you can drive in forward when transporting a full bucket out of the digging area.

• Whenever possible, drive in reverse when transporting a full bucket down a steep slope.

Loading trucks When loading trucks, we recommend the following: • The truck and loader working direction should form an angle of 45°.

• Only raise a full bucket to the dump height when you are driving in a straight line toward the truck.

• Dump with the wind behind you to keep the dust away from your eyes, air filters, and fans.

Freeing the wheel loader If your machine gets stuck in soft ground:

☞ Dump out the bucket until the blade is vertical above the ground. ☞ Completely lower the boom. ☞ Gradually tilt in the bucket. ➥ The machine is pushed rearward. ☞ Reverse slowly. ☞ Repeat this procedure until the wheels reach firm ground. ☞ Reverse the machine away.

Printed in U.S.A.

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Operation Working with the pallet forks • Follow the instructions in the attachment's Operator’s Manual.

a

• Before working, be sure that the fork arms on the fork frame are safely locked.

• Maintain a minimum distance of 19’7” (6 m) between loader unit/load and overhead lines.

• Always approach the material with the machine wheels in straight-ahead position.

• Always tilt the forks slightly back (toward the machine) for transport.

• Always transport the load close to the ground.

• Always load on firm and level ground with sufficient load-bearing capacity (for a fully loaded machine).

• Only set loads onto designated areas, with a stable base, that have load-bearing capacity.

• Only stack loads up to the authorized maximum pallet height.

• Only place loads in designated areas within the construction site.

• Move the fork arms all the way under a pallet, as far as they will go, so that the load is picked up as closely as possible to the fork frame.

b

• Move under the load with the straight fork arms as far apart as possible and at an equal distance to the left and right side of the load (figure b).

• Lock the adjustable fork arms with the locking lever before moving the machine (with loaded or unloaded pallet forks).

• Lower the forks as closely as possible to the ground for transport. Follow minimum ground clearance.

• Drive slowly with a raised load, especially in off-road applications, to avoid swinging movements of the load.

• When driving or working across a slope, the load must be on the uphill side of the machine/attachment.

• On sloping terrain, drive the machine rearward to prevent the load from falling off and the machine from tilting forward when braking.

• When transporting large bulk loads, drive the machine rearward for improved visibility.

• Learn the load bearing capacity of bridges, basement ceilings, vaults, and similar structures before moving the machine onto them.

• Learn the clearances of underpasses, tunnels, gates, and similar structures before driving through or under them.

• Follow the load bearing capacity of the set-down area (e.g., truck platforms, storage area in high-bay warehouses).

• Load the vehicles or trailers evenly.

• Position and distribute the load evenly on the front tires.

126801d0.ai

• Never raise a load with only one fork arm.

• Never operate the machine and attachment at high speeds.

• Never leave the machine with the load raised.

• Never use the controls, movable lines, or cables as handles.

• Never use bent, cracked or damaged fork arms/pallet forks.

• Never work or stand under suspended loads (figure a).

• DO NOT transport people in the attachment.

• DO NOT stack or set down loads that are not properly packaged, have shifted in higher places, or have damaged pallets/stacking containers.

• DO NOT overload the attachment or the machine - follow the load diagram.

• DO NOT exceed the authorized maximum pallet height.

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Operation • DO NOT set down loads too near slopes, construction pits, fire escape routes, equipment that you need to access at all times, etc.

Overview of fork arms

These instructions are based on the “Guidelines for testing and repairing fork arms” (© by VETTER Umformtechnik GmbH): • Only use fork arms according to their designed use.

• Only the manufacturer is authorized to complete repair work on the fork arms.

• Always keep fork arms clean.

• Load both fork arms evenly.

• Tie down loads to avoid losing them.

• Complete regular checks according to the Operator’s Manual.

• DO NOT exceed the load center and lifting capacity.

• DO NOT use standard fork arms as reverse forks.

• DO NOT push, pull or shove the fork arms, or move them in at a slanting angle (risk of damaging them due to lateral forces).

• DO NOT pull off loads, or allow them to fall onto the fork arms.

• DO NOT raise by using the tilt cylinder (tilt device).

• DO NOT modify the fork arms, or attach any additional device.

• DO NOT transport people on the fork arms.

• DO NOT transport molten material.

• DO NOT perform any cable-laying work.

• The operator must regularly check: • Lock: Functional check.

• Hooks:

Visual check for cracks and deformations.

• Bend:

Visual check for dents, nicks and cracks.

• Bend and blade: • Blade and tip:

Do not use any longer if worn over 10%.

Check for deformations.

• Wear on fork arms:

See service manual or manufacturer.

• In case of damage: Stop using the fork arms.

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Operation Fitting the attachment onto the quickhitch facility ☞ Pick up the attachment ➥ – see Locking: Attachments without hydraulic function on page 76.

WARNING! The attachment must always be safely locked onto the quickhitch facility –

Accident risk. ☞ Before working, make sure the attachment is safely locked onto the quickhitch facility by using the lock cylinder.

Fig. 103: Checking the lock pins

➥ You must be able to see the lock pins on both sides of the mounting holes on the attachment.

Removing the pallet forks from the quickhitch facility WARNING! The attachment must be placed on the ground so that it will not fall over when removed –

Risk of personal injury. ☞ Position the attachment so that after unlocking it will stand safely and not tip over.

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Operation Adjusting the fork arms

WARNING! If the fork arms are not secured to avoid lateral sliding or slipping –

Accident risk. ☞ Before using the pallet forks, be sure that both locking levers on the forks

are folded down. This locks the safety pins of the fork arms in the notches on the fork frame, and prevents the fork arms from slipping or sliding.

When you position the fork arms under the load, make sure that they have the greatest possible space between them.

Always evenly align the fork arms to the fork frame.

126801f0.ai

If necessary, adjust the spacing of the fork arms as follows:

☞ Set the locking lever to the vertical position a. ➥ The fork arms can be moved on the fork frame. ☞ Slide the fork arms to the required distance until the safety pin engages in a slot on the

a

fork frame.

☞ Fold down locking lever again, position b. ➥ The upper edge of the locking lever must be flush with the edge c.

b

c

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Operation Load diagram The load diagram is located in the cab (front window) of the machine, values are calculated for the respective machine model – see Use: attachment on page 9.

WARNING! If you exceed the maximum loads stated, the machine may become unstable.

Rated operating load, standard bucket - lbs (kg) 2590 (1175)

Printed in U.S.A.

90

Rated operating load, pallet forks - lbs (kg) 2205 (1000)

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Operation Picking up loads with the pallet forks ☞ Move the wheel loader up to the load so that the forks are at a right angle to the load. ➥ The fork arms must both be at the farthest possible distance apart, and at an equal distance to the left and right side of the load.

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☞ Drive the wheel loader forwards and position the fork arms as far as possible underneath the pallet. ➥ The load must fit closely to the fork frame.

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☞ Carefully raise the load.

WARNING! Do not exceed the machine's output limit, otherwise the machine may become unstable.

☞ Follow the load diagram – see Load diagram on page 90.

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☞ Tilt in the load slightly rearward.

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Operation Transporting loads with the pallet forks DANGER! When transporting loads with the pallet forks raised, the load can fall down or the machine can tilt –

Accident risk.

When turning or driving on slopes, the center of gravity must always be in the lowest possible position.

☞ To avoid accidents: • Tilt the pallet forks slightly rearward.

• Lower the pallet forks to the transport position, and only raise them (if necessary) just before setting down the load.

• Never raise the load over persons.

• Never park the machine with a raised load.

• Avoid any operation that might be a risk to machine stability.

☞ Only move the load after it is placed on the fork arms. ☞ Only move the machine after you have sufficient visibility.

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☞ Lower/raise loads to the transport position before moving them (ground clearance – see Checking the transport position of the bucket on page 80).

If necessary, increase ground clearance for off-road applications.

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☞ Always tilt the pallet forks slightly back (toward the machine) for transport. ☞ Always drive slowly (especially in off-road applications) to avoid strong swinging movements.

☞ When driving or working across a slope, the load must be on the uphill side of the machine/attachment.

☞ Drive the machine rearward on sloping terrain to prevent the load from falling off and the machine from tilting forward when braking.

☞ Drive the machine rearward when transporting large bulk loads for improved visibility.

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Operation Working with the multipurpose bucket Fitting the multipurpose bucket onto the quickhitch facility ☞ Fit the multipurpose bucket: ➥ – see Fitting attachments onto the quickhitch facility on page 75. ☞ Make sure both lock pins of the lock cylinder are safely locked in the attachment.

WARNING! The attachment must always be safely locked onto the quickhitch facility –

Accident risk. ☞ Before working, make sure the attachment is safely locked onto the quickhitch facility by means of the lock cylinder.

➥ You must be able to see the lock pins on both sides of the mounting

Fig. 104: Checking the lock pins

holes on the attachment.

☞ Make sure the lock pins of the quickhitch facility are fully extended before coupling the hydraulic lines of any additional control circuit to the attachment.

Hydraulic connections on the multipurpose bucket

230 bar

D

Hydraulic connection

Function

C Pressurized

Opens the multipurpose bucket.

D Pressurized

Closes the multipurpose bucket.

C Hydr_plan.eps

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Operation Connecting hydraulic lines to the machine B A

☞ Turn off the engine. ☞ Apply the parking brake. ☞ Depressurize the hydraulic lines ➥ – see Depressurizing the quick couplers on the loader unit on page 74. ☞ Remove hydraulic lines A and B from the quickhitch facility.

Fig. 105: Removing hydraulic quickhitch connections

B

☞ Connect hydraulic lines A and B to hydraulic connections C and D of the attachment.

A

IMPORTANT!

C

D

Fig. 106: Connecting hydraulic multipurpose bucket lines

Printed in U.S.A.

Make sure the quick couplers are properly connected – never cross-connect the hydraulic lines, cross-connecting inverts the attachment functions, and may cause the hydraulic lines to be squeezed or damaged when you dump or tilt the attachment – see Multipurpose bucket operation on page 96.

☞ Functional check: • Make sure that the hydraulic lines cannot be squeezed throughout the entire moving range of the attachment.

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Operation Removing the multipurpose bucket from the quickhitch facility

WARNING! The attachment must be placed on the ground so that it will not fall over when removed –

Risk of personal injury. ☞ Position the attachment so that after unlocking it will stand safely and not tip over.

IMPORTANT! Placing the attachment in direct sunlight after removing it causes the oil in the hydraulic cylinders to warm up. This creates a pressure increase in the hydraulic cylinders that makes it difficult to attach the hydraulic lines to the hydraulic connections.

To avoid this problem, remove the attachment as follows: B

☞ Tilt in the multipurpose bucket completely. ☞ Close the multipurpose bucket to a gap of about 8” (20 cm). ☞ Unlock the multipurpose bucket. ➥ – see Unlocking: on page 73. ☞ Turn off the engine. ☞ Apply the parking brake. ☞ Depressurize the hydraulic lines. ➥ – see Depressurizing the quick couplers on the loader unit on page 74. ➥ Multipurpose bucket closes, depressurized. ☞ Remove hydraulic lines A and B from quick couplers E and F on the multipurpose

A

F E

bucket.

Fig. 107: Removing hydraulic multipurpose bucket connections

☞ Connect hydraulic lines A and B onto quick couplers C and D of the quickhitch facility.

B A

IMPORTANT! Make sure that the quick couplers are properly connected, never crossconnect the hydraulic lines, cross-connecting inverts the functions of the quickhitch cylinder.

D C Fig. 108: Connecting hydraulic quickhitch lines

Printed in U.S.A.

After connecting the hydraulic cylinder of the quickhitch facility, as described above: ☞ Slightly dump out the multipurpose bucket to a horizontal position.

➥ – see Removing an attachment from the quickhitch facility on page 77. ☞ Set down the multipurpose bucket.

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Operation Multipurpose bucket operation

WARNING! The attachment must always be safely locked onto the quickhitch facility –

Accident risk. ☞ Before working, make sure that the attachment is locked onto the quickhitch facility by using the lock cylinder. You must be able to see the lock pins on both sides of the mounting holes on the attachment – see Locking: Attachments without hydraulic function on page 76.

Driving on public roads with the multipurpose bucket – see Before driving the machine on page 46.

☞ Tilt in the multipurpose bucket completely (to the basic position). ☞ Uncouple the hydraulic lines from the multipurpose bucket and connect them to the

quickhitch facility ➥ – see Removing the multipurpose bucket from the quickhitch facility on page 95.

☞ Set the multipurpose bucket to the transport position ➥ – see Before driving the machine on page 46. ☞ If necessary, mount removable parts on the machine (rotating beacon, light strip or additional clearance lights, etc.).

☞ If necessary, check the function of the lights. ☞ Lock the control lever (joystick) ➥ – see Control lever lock (joystick) on page 47.

– see Use: attachment on page 9.

IMPORTANT! Additional rear lights, a rotating beacon, and other items are not included as standard equipment. They are provided separately. You may need additional clearance lights if the attachment protrudes by more than 16” (400 mm) over the clearance lights of the machine.

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Operation Grading and scraping Transporting with a full bucket WARNING! Do not transport full attachments in the raised position –

Accident risk.

The lower the position of the attachment, the lower the center of gravity, i.e., the less risk there is of tilting.

☞ To avoid accidents: • Tilt in the attachment completely.

• Lower the attachment to the transport position.

Grading

☞ Fold up the front half of the bucket. ☞ Set the depth of the layer you want to remove with the lift hydraulics. ☞ Set the angle of the rear cutting edge.

Skimming material

☞ Dump out the multipurpose bucket. ☞ Raise the bucket with the lift hydraulics. ☞ Fold up the front half of the bucket. ☞ Lower the multipurpose bucket to the ground. ☞ Set the angle of the bucket. ☞ Surfaces are graded or scraped when driving in reverse.

Stripping in thin layers (scraper)

☞ Set a flat digging angle. ☞ Fold up the front half of the bucket by 4 to 6” (10 to 15 cm). ☞ Drive the machine forward. ➥ The material rolls into the bucket and is picked up at the same time.

NOTE: This position allows the attachment to strip (e.g., grass turf) down to a thickness of about 3” (8 cm).

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Operation Spreading material in thin layers

☞ Set the rear cutting edge parallel to the ground. ☞ Fold up the front half of the bucket until the required quantity of material is emptied onto the ground.

☞ Drive the machine forward. ☞ Lower the multipurpose bucket to the ground. ➥ The rear cutting edge grades the material as it is emptied by opening the front half of the bucket.

This position allows to spread material without maneuvering on the lower layer with the machine (e.g., applying the first bituminous base onto sensitive antifrost layers, applying granulated material onto plastic coatings).

Pulling out material from slopes This position allows you to pull from slopes or roadside ditches with maximum safety and to spread it as required.

Moving material with longer reach This allows you to move material without damaging slopes or structures. ➥ Backfilling with maximum safety and without damaging slopes.

48GREIF6.eps

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Operation Grab operation Picking up remaining material completely

NOTE: Both bucket halves must touch the ground so that all the material is picked up.

☞ Fold up the front half of the bucket (multipurpose bucket). ☞ Dump out the bucket. ☞ Lower the bucket to the ground. Make sure both bucket halves touch the ground. ☞ Close and tilt in the multipurpose bucket at the same time. ☞ Raise the bucket with the lift hydraulics.

Grabbing bulky material

➥ The multipurpose bucket allows to safely grab, pick up and transport building timber, reinforcement bars, packaging bands, wire, etc.

Grabbing large objects

➥ The multipurpose bucket allows you to safely grab, pick up and transport large objects.

Pulling out and setting posts

☞ Open the multipurpose bucket and lower it over the post. Close the bucket to grip the post firmly.

☞ Loosen the post by carefully moving the bucket up and down.

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Operation Unloading from the bottom of the bucket Precise unloading

➥ Precise dozing and placement of pourable material.

Backfilling round gravel into drainage ditches

➥ Bucket teeth move back from the wall as the bucket opens.

Unloading from the bottom of the bucket for increased dump heights

➥ Increases the dump height by at least 22” (55 cm) (depending on bucket size), as compared to dumping with a standard bucket.

NOTE: Smaller dump reach is compensated by pushing the material with the open multipurpose bucket as shown.

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Operation Working with the Skid-A-Tach TM adapter (option) ➥ – see Use: attachment on page 9.

WARNING! The attachment must always be safely locked onto the quickhitch facility –

Accident risk. ☞ Before working, make sure that the attachment is safely locked onto the

quickhitch facility by means of the lock cylinder. You must be able to see the lock pins on both sides of the mounting holes on the attachment.

☞ Make sure the lock pins of the quickhitch facility are fully extended before coupling the hydraulic lines of any additional control circuit to the attachment.

Mounting an attachment adapter onto the quickhitch facility

☞ Mounting and connecting the hydraulic hoses to the quickhitch facility: ➥ – see Fitting the multipurpose bucket onto the quickhitch facility on page 93. ☞ Removing the attachment adapter. ➥ – see Removing an attachment from the quickhitch facility on page 77.

Mounting an attachment onto the attachment adapter

☞ See the attachment's Operator’s Manual for mounting and connecting the hydraulic hoses to the attachment.

WARNING! The attachment must be locked onto the Skid-A-TachTM –

Accident risk. ☞ Before working, make sure the attachment is safely locked with the Skid-A-

TachTM by means of lock pins 1 on the left and right. You must be able to see the lock pins on both sides of the mounting holes on the Skid-A-TachTM.

Fig. 109: Locking the attachment with the attachment adapter

Printed in U.S.A.

☞ Changing the hydraulic hoses (similar to multipurpose bucket). ➥ – see Fitting the multipurpose bucket onto the quickhitch facility on page 93. ➥ – see Attachments with hydraulic function on page 76.

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Operation Notes:

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Troubleshooting

Troubleshooting

Troubleshooting Use this section to determine malfunctions and repair solutions.

Engine trouble Problem

Possible causes

See page

Engine starting temperature is too low

Engine does not start or is not easy to start

Wrong SAE grade of engine lubrication oil

129

Fuel quality does not comply with specifications

129

Battery defective or flat

125

Loose or oxidized cable connections in starter circuit Starter defective, or pinion does not engage Wrong valve tip clearance Fuel injector defective Fuel quality does not comply with specifications

Engine starts, but does not run smoothly

129

Wrong valve tip clearance Injection line leaks Fuel injector defective Oil level too low

107

Oil level too high

107

Air filter not working

111

Air filter maintenance switch or gauge defective

111

Engine overheats, temperature warning system responds Oil cooler fins not working Fan defective, V-belt torn or loose

111

Cooling air heats up Resistance in cooling system too high, flow capacity too low Fuel injector defective

Insufficient engine output

Oil level too high

107

Fuel quality does not comply with specifications

129

Air filter not working

111

Air filter maintenance switch or gauge defective

111

Wrong valve tip clearance Injection line leaks Fuel injector defective Engine does not run on all cylinders

Printed in U.S.A.

Injection line leaks Fuel injector defective 103

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Troubleshooting Problem

Insufficient or no engine oil pressure

Possible causes

See page

Oil level too low

107

Engine inclination too high

Engine oil consumption too high

Wrong SAE grade of engine lubrication oil

129

Oil level too high

107

Engine inclination too high Blue

Oil level is too high

107

Engine inclination is too high Engine starting temperature is too low

White Engine smoke

Fuel quality does not comply with specifications

129

Wrong valve tip clearance Fuel injector defective

Black

Air filter not working

111

Air filter maintenance switch or gauge defective

111

Wrong valve tip clearance Fuel injector defective

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Maintenance

Maintenance

Maintenance Introduction Operational readiness and the service life of the machine can be increased through proper maintenance.

Before carrying out service and maintenance work, always read, understand and follow the instructions given in: • – see Safety instructions on page 15.

• The Operator’s Manuals of the attachments.

Daily service and maintenance work, and maintenance according to maintenance schedule “A” must be completed – see Maintenance schedule Model ML28 (overview) on page 131.

Fuel system

DANGER! • When handling fuel, there is a high risk of fire.

Safety instructions

• Never work on the fuel system around open flames or sparks.

• DO NOT smoke when working on the fuel system or refueling.

• Before refueling, turn off the engine and remove the ignition key.

• Do not refuel in closed rooms.

• Wipe up fuel spills immediately.

• Keep the machine clean to reduce the risk of fire.

Refueling Filler inlet A for the fuel tank is located under the engine cover, on the left side.

Environment!

Use a suitable container to collect the fuel as it drains and dispose of it in an environmentally friendly manner.

A IMPORTANT! Fig. 110: Fuel filler inlet

Do not run the fuel tank completely dry. Otherwise, air is drawn into the fuel system. This requires bleeding the fuel system – see Bleeding the fuel system on page 106.

Stationary fuel pumps General Only refuel from stationary fuel pumps. Fuel from barrels or canisters can be contaminated.

Even the smallest particles of dirt can cause: • Increased engine wear.

• Malfunctions in the fuel system.

• Reduced effectiveness of the fuel filters.

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Maintenance Diesel fuel specification

Only use high-grade fuels.

Cetane number

Grade No. 2-D according to DIN 51601.

No. 1-D according to DIN 51601.

Use For normal outside temperatures.

Min. 45

For outside temperatures below 39°F (4°C) or for operation above 4’9” (1500 m) altitude.

Bleeding the fuel system DANGER! If the fuel, as it drains, comes into contact with hot engine parts or the exhaust system, there is an increased:

Risk of burns. ☞ Never bleed the fuel system if the engine is hot.

Bleed the fuel system in the following cases: • After removing the fuel filter or prefilter, and removing and fitting the fuel lines back on again:

A B

1

• After running the fuel tank empty.

• After running the engine again, after it has been out of service for a long period of time.

2

☞ Bleed the fuel system as follows: • Fill the fuel tank.

• Open fuel cock 1 on the fuel filter. To do this: Turn lever from A to B. • Slacken bleed screw 2 on the injection pump by a few turns.

3 Fig. 111: Bleeding the fuel system

• Turn the lever on fuel pump 3 manually until the fuel comes out free of air from the slackened bleed screw.

• Tighten bleed screw 2 on the fuel injection pump.

• Start the engine – see Starting the engine on page 43.

If the engine does not run smoothly or stops: • Turn off the engine.

• Check once again if there is any air in the fuel system.

• Bleed the fuel system again as described above.

• Have the engine checked by authorized service technicians.

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Maintenance Engine lubrication system IMPORTANT! If the engine oil level is too low or if an oil change is overdue, this may cause engine damage or loss of output.

☞ Have the oil changed by an authorized dealer – see Maintenance schedule Model ML28 (overview) on page 131.

Checking the oil level IMPORTANT! Check the oil level before starting the engine and after every 10 service hours or daily (if you use the machine for less than 10 service hours in one day). After turning off a warm engine, wait at least 5 minutes before checking the oil level.

Checking the oil level Proceed as follows:

A max min

☞ Park the machine on level ground. ☞ Turn off the engine – see Parking the machine on page 51.

☞ Apply the parking brake. ☞ Open the engine cover. ☞ Pull out oil dipstick A: • Wipe it with a lint-free cloth.

• Push it back in as far as possible.

• Pull it out and read off the oil level. ☞ You must fill the oil tank when the oil level reads at the MIN mark on the oil dipstick A

Fig. 112: Checking the oil level

Printed in U.S.A.

– see Adding engine oil on page 108.

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Maintenance Adding engine oil

IMPORTANT! Excessive or incorrect engine oil may result in engine damage. For this reason:

☞ Do not add engine oil above the MAX mark of oil dipstick 112/A. ☞ Only use the engine oil specified – see Fluids and lubricants on page 129.

Environment!

Use a container to collect the engine oil as it drains and dispose of it in a manner consistent with environmental laws.

Adding engine oil OIL

A

☞ Proceed as follows: • Clean the area around oil filler cap B by using a lint-free cloth.

• Open filler cap B.

B

• Raise oil dipstick A slightly to allow any trapped air to escape.

• Add engine oil.

• Wait a moment until all the oil has run into the oil sump.

• Check the oil level– see Checking the oil level on page 107.

• Add oil if necessary and check the level again.

• Close filler cap B. • Push oil dipstick A back in as far as possible.

Fig. 113: Oil dipstick and oil filler cap

Printed in U.S.A.

• Completely remove any oil spilt from the engine.

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Maintenance Engine and hydraulics cooling system The combined engine/hydraulic oil cooler is located in the engine compartment, on the right side, next to the engine. It cools the diesel engine, hydraulic oil of the drive and the work hydraulics.

The expansion tank for the coolant is located in the engine compartment on the right side, in front of the battery.

Specific safety instructions

• Dirt on the cooling ribs reduces the cooler’s heat dissipation capacity. To avoid this:

☞ Clean the outside of the cooler at regular intervals – see Maintenance schedule Model ML28 (overview) on page 131.

☞ In dusty or dirty work conditions, clean more frequently than the maintenance schedule states.

• An insufficient coolant level reduces the heat dissipation capacity as well, and can lead to engine damage. Therefore: ☞ Check the coolant level at regular intervals – see Maintenance schedule Model ML28 (overview) on page 131.

☞ If coolant must be added frequently, check the cooling system for leaking and/or contact your dealer.

IMPORTANT! Never add cold water/coolant if the engine is warm.

☞ After filling the expansion tank, run and turn off the engine, then check the coolant level.

IMPORTANT! The use of the wrong coolant can destroy the engine and the cooler.

Therefore: • Add sufficient antifreeze compound to the coolant – but never more than 50%. If possible use brand-name antifreeze compounds with anticorrosion additives.

• DO NOT use cooler cleaning compounds if an antifreeze compound has been added to the coolant, because this causes sludge to form, which can damage the engine.

☞ Follow the coolant compound table – see Coolant compound table on page 148.

Environment!

Use a container to collect the engine oil as it drains and dispose of it in a manner consistent with environmental laws.

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Maintenance Checking/filling up the coolant level Check both the coolant and oil levels before starting the engine and after every 10 service hours (or daily if you use the machine for less than 10 service hours in one day).

A

B

Fig. 114: Expansion tank for coolant

☞ Proceed as follows: • Park the machine on level ground.

• Turn off the engine – see Parking the machine on page 51.

• Apply the parking brake.

• Open the engine cover.

• Check the coolant level in the transparent expansion tank A. ☞ If the coolant level is below marking LOW on the expansion tank, fill up the coolant level.

DANGER! The cooling system is under high pressure – never open the coolant tank and never drain coolant if the engine is warm:

Risk of burns. ☞ Wait at least 10 minutes after turning off the engine. ☞ Wear protective gloves and clothing. ☞ Open filler cap B to the first notch and allow pressure to escape. ☞ Press filler cap B down to reduce the pressure in the radiator. ☞ Open the cap to the first notch and allow the pressure to escape. ☞ Open filler cap B. ☞ Add coolant up to the lower edge of the radiator. ☞ Close filler cap B. ☞ Start the engine and let it warm up for about 5 – 10 minutes. ☞ Turn off the engine and check the coolant level again. ➥ The coolant level must be between markings LOW and FULL. ☞ If necessary, add coolant and repeat the procedure until the coolant level remains constant.

Printed in U.S.A.

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Maintenance

Maintenance Air filter IMPORTANT! The filter cartridge will be damaged if it is washed or brushed out.

To avoid premature engine wear:

☞ DO NOT clean the filter cartridge. ☞ Replace the filter cartridge when the indicator comes on. ☞ Never reuse a damaged filter cartridge. ☞ Ensure cleanliness when replacing the filter cartridge.

Weekly air filter contamination check

Air filter restriction indicator display B on the filter housing monitors the filter cartridge.

☞ Filter cartridge D must be replaced:

A

• If the red mark C in maintenance display B is visible.

B

• After 1500 service hours (or yearly if you use the machine for less than 1500 service hours during one year) – see Replacing the filter cartridge on page 112.

C

IMPORTANT! For dusty environments, the air filter is fitted with an extra safety cartridge F. DO NOT clean the safety cartridge. Replace the safety cartridge every third time maintenance work is performed.

D IMPORTANT! 34001b520_02.iso

E

F

Fig. 115: Air filter with maintenance display

Filter cartridges degrade prematurely when you use the machine in acidic air for long periods of time. Acidic air is present, for example, in acid production facilities, steel and aluminium mills, chemical plants, and other nonferrousmetal plants.

☞ Replace filter cartridge D and safety cartridge F after 500 service hours – see Replacing the filter cartridge on page 112.

Weekly dust valve functional check

☞ Proceed as follows: • Squeeze the discharge slot of dust valve E. • Remove hardened dust by compressing the upper area of the valve.

☞ Clean the discharge slot if necessary.

Fig. 116: Air filter – dust valve

Printed in U.S.A.

E

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Maintenance Replacing the filter cartridge ☞ Replace filter cartridge D as follows:

G

• Turn off the engine.

• Prevent the machine from rolling away and remove the ignition key – see Parking the machine on page 51.

• Open the engine cover.

H

• Fold both bow clips G on lower housing section H to the outside.

• Remove lower housing section H. • Carefully remove filter cartridge D by using slight turning movements.

• Every third time you replace the filter:

307b0700.ai

Fig. 117: Removing the lower housing section

• Carefully remove safety cartridge 115/F.

D

• Make sure all contamination (such as dust) inside the upper and lower housing sections is removed.

• Carefully insert a new safety cartridge 115/F into the upper housing section.

• Carefully insert new filter cartridge D into the upper housing section.

• Position lower housing section H (make sure it is properly seated).

• Close both bow hooks G.

307b0710.ai

Fig. 118: Removing the filter element

☞ After filter replacement:

A B

• Press reset button A to reset the red mark C (visible in the display maintenance window of indicator B).

C

Fig. 119: Air filter with maintenance display

Printed in U.S.A.

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Maintenance V-belt DANGER! Only check, re-tension, or replace the V-belt after the engine is turned off –

Risk of personal injury. ☞ Turn off the engine before working on or around the engine.

IMPORTANT! Cracked and stretched V-belts cause engine damage.

☞ Have the V-belt replaced by an authorized dealer.

Check the V-belt after 10 service hours (or daily if you use the machine for less than 10 service hours in one day). Re-tension the V-belt if necessary.

Re-tension new V-belts after about 15 minutes of running time.

Checking V-belt tension ☞ Check the V-belt tension as follows:

2

• Turn off the engine.

• Prevent the machine from rolling away and remove the ignition key – see Parking the machine on page 51.

1

• Open the engine cover.

About 0.39” (10 mm)

• Carefully inspect V-belt 1 for damage.

• If the V-belt is damaged: • Have the V-belt replaced by authorized staff.

• Press with your thumb to check whether the V-belt cannot be deflected between the pulleys by more than about 0.39” (10 mm) 2.

• Re-tension the V-belt if necessary. See below.

Fig. 120: Checking V-belt tension

Re-tensioning the V-belt

☞ Re-tension the V-belt as follows: • Turn off the engine.

• Prevent the machine from rolling away and remove the ignition key – see Parking the machine on page 51.

3

• Open the engine cover.

• Slacken attachment screws 3 of alternator 4.

A 4 Fig. 121: Re-tensioning the V-belt

Printed in U.S.A.

• Use a suitable tool to push the alternator in the direction of arrow A until the correct V-belt tension is obtained (fig. 120).

• Keep the alternator in this position, and at the same time tighten attachment screws 3.

• Check the V-belt tension (fig. 120) again.

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Maintenance Hydraulic system Safety instructions • You must depressurize all lines carrying hydraulic oil before performing any maintenance or repair work. To do this: • Lower all hydraulically controlled attachments to the ground.

• Actuate all control levers of the hydraulic control valves several times.

• Apply the parking brake to prevent the machine from rolling away before you perform service and maintenance work.

WARNING! Hydraulic oil escaping under high pressure can penetrate the skin and cause serious injuries. Always consult a doctor immediately, even if the wound appears insignificant, to be sure that serious infections do not set in.

IMPORTANT! If the hydraulic oil in the level glass is cloudy, this indicates that water or air has penetrated the hydraulic system. This may damage the hydraulic pump.

IMPORTANT! Insufficient, incorrect, or contaminated hydraulic oil –

Risk of severe damage to the hydraulic system. ☞ Always add hydraulic oil by using the filling screen. ☞ Only use the same type of authorized oils – see Fluids and lubricants on page 129.

☞ Always add hydraulic oil before the level gets too low. ☞ If the hydraulic system is filled with biodegradable oil, only use the same type of biodegradable oil, following the label on the hydraulic oil tank.

☞ Contact your Mustang dealer if the hydraulic system filter is contaminated with metal chippings. Otherwise, damage may result.

Environment!

Collect hydraulic oil, including biodegradable oil, with a container. Dispose of drained oil and used filters in accordance with environmental laws.

Always contact the authorities or establishments in charge of oil disposal before disposing of biodegradable oil.

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Maintenance Checking the hydraulic oil level ☞ Proceed as follows: • Park the machine on level ground.

• Retract all hydraulic cylinders.

A

• Turn off the engine.

✓

• Apply the parking brake.

• Open the engine cover.

• Check the hydraulic oil level in sight glass A. If the oil level is lower than in fig. A, add hydraulic oil.

Fig. 122: Oil level sight glass on the hydraulic oil tank

Adding hydraulic oil

IMPORTANT! Only add hydraulic oil to the hydraulic oil tank if the engine is turned off. If the engine is turned on, hydraulic oil will run out of the filler opening and onto the hydraulic tank.

☞ Add oil as follows: • Park the machine on level ground.

• Retract all hydraulic cylinders.

• Turn off the engine.

• Apply the parking brake.

• Open the engine cover.

B

• Clean the area around the filler and breather filter B by using a cloth.

• Open breather filter B. With the filter insert in place: • Add hydraulic oil until the tank is full.

• Check the hydraulic oil level on oil level sight glass A. • Add more oil if necessary and check again.

• Firmly close breather filter B.

A ✓

Fig. 123: Hydraulic oil tank

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Maintenance Important information about the use of biodegradable oil • Only use the biodegradable hydraulic fluids that have been approved by Mustang – see Fluids and lubricants on page 129. Always contact your Mustang dealer for the use of other products that have not been recommended. In addition, ask the oil supplier for a written guarantee. This guarantee is applicable to damage occurring on the hydraulic components, which can be proved to be due to the hydraulic fluid.

• Only use the same type of biodegradable oil when filling up. A decal stating the oil used is located on the hydraulic oil tank (next to the filler inlet).

IMPORTANT! Replace missing decals.

• Using two different biodegradable oils at the same time can affect the quality of one of the oils. When changing biodegradable oil, be sure that the remaining amount of initial hydraulic fluid in the hydraulic system does not exceed 8% (manufacturer indications).

• DO NOT top off with mineral oil – the content of mineral oil should not exceed 2%.

• If hydraulic attachments are mounted or operated, use the same type of biodegradable oil for these attachments to avoid mixtures in the hydraulic system.

• If you are running the machine with biodegradable oil, the same oil and filter replacement intervals used for mineral oil are valid – see Maintenance schedule Model ML28 (overview) on page 131.

• Have an authorized dealer drain the condensation water in the hydraulic oil tank after every 500 service hours (or before the cold season if you have not yet used your machine for 500 service hours). The water content must NOT exceed 0.1% by weight.

• All environmental instructions stated in this manual are valid for the use of biodegradable oil.

IMPORTANT! A change from mineral to biodegradable oil must be carried out by an authorized dealer.

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Maintenance Checking hydraulic pressure lines Safety instructions DANGER! Hydraulic oil escaping under high pressure can penetrate the skin and cause serious injuries.

Risk of personal injury. ☞ Always consult a doctor immediately, even if the wound appears insignificant, to be sure that serious infections do not set in.

☞ Always follow these instructions: • Only tighten leaking screwed fittings and hose connections after you have released the pressure.

• Only use paper or wood to check for minor leaks, never use an unprotected light or open flame.

• Only authorized dealers should replace damaged flexible lines.

• Never weld faulty or leaking pressure lines and connections, always replace damaged parts with new ones.

• Never search for leaks with your bare hands, always wear protective gloves.

• An authorized workshop or after-sales staff should immediately repair or replace any leaking or damaged pressure lines.

1 Q/04

• Replace hydraulic hoses every six years from the date of manufacture, even if they do not appear to be damaged.

The date of manufacture (month or quarter and year) is stated on the flexible line.

Example: The indication “1 Q/04” means manufactured in the 1st quarter of 2004.

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Maintenance Notes:

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Maintenance

Maintenance Lubrication points Lubricate all points listed below with lithium-based brand-name grease – see Fluids and lubricants on page 129.

Lubricating the rear axle oscillation-type bearing IMPORTANT! The machine has an oscillation-type rear axle. The bearing must be greased after every 50 service hours (or weekly if you use the machine for less than 50 service hours during one week).

A

The grease nipple is located above the axle tube, on the left side.

☞ Lubricate grease nipple A of the oscillation-type bearing.

Fig. 124: Grease nipples for oscillation-type bearing

Lubricating the planetary drive bearing ☞ Lubricate grease nipples B on each planetary drive bearing every 50 service hours (or weekly if you use the machine for less than 50 service hours during one week).

B

Fig. 125: Grease nipples on planetary drive bearings

Lubricating the loader unit Lubricate the following points on the loader unit C

☞ Lubricate grease nipples C on the machine bearing every 50 service hours

(or weekly if you use the machine for less than 50 service hours during one week).

Lubricate daily during heavy-duty operation.

Fig. 126: Upper lubrication points on machine

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Maintenance ☞ Lubricate grease nipples D on the lift cylinder bearing every 50 service hours

(or weekly if you use the machine for less than 50 service hours during one week).

Lubricate daily during heavy-duty operation.

☞ Lubricate grease nipples E on the tilt cylinder bearing with grease every 50 service hours (or weekly if you use the machine for less than 50 service hours during one week). Lubricate daily during heavy-duty operation.

D

E

Fig. 127: Lubrication points for lift and tilt cylinder bearings

☞ Lubricate grease nipples F on the tilt rod bearing with grease every 50 service hours (or weekly if you use the machine for less than 50 service hours during one week).

Lubricate daily during heavy-duty operation.

F

Fig. 128: Lubrication points on tilt rod bearing

☞ Lubricate grease nipple G on the tilt lever bearing every 50 service hours G

(or weekly if you use the machine for less than 50 service hours during one week).

Lubricate daily during heavy-duty operation.

Fig. 129: Lubrication points on tilt lever bearing

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Maintenance ☞ Lubricate grease nipples H on the quickhitch bearing every 50 service hours

(or weekly if you use the machine less than 50 hours in one week). Lubricate daily during heavy-duty operation.

H

Fig. 130: Lubrication points on quickhitch facility

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Maintenance Tire care WARNING! Improper tire repairs are an:

Accident risk. ☞ All repair work on tires and rims may only be completed by authorized specialist dealers.

IMPORTANT! Regular inspection of the tires: • Improves operating safety.

• Increases the service life.

• Can reduce machine downtime – see Specifications on page 141 for the authorized tire types and the correct tire pressures. Machines are also delivered with a tire table decal on the front window or the loader unit bulkhead.

Tire check Daily check

☞ Complete the following maintenance work daily: • Check tire pressure.

• Check the inside and outside of tires and rims for damage (cracks, aging, etc.).

• Remove objects from the tire tread.

• Remove oil and grease.

Weekly check

☞ Complete the following maintenance work weekly: • Check tires for wear and measure tread depth.

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Maintenance Wheel change

DANGER! Using the wrong tires or wheels –

Accident risk. ☞ Only use authorized wheels and tires – see Tires on page 147.

☞ Check the wheel nuts for tightness after every wheel or tire change.

IMPORTANT! The wheels are heavy and can damage the threads on the wheel studs if they are not handled correctly.

☞ Use suitable assembly tools, such as covering sleeves for the studs, a jack, etc.

Removing the wheels

☞ Proceed as follows: • Park the machine on level and firm ground, prevent it from rolling away – see Parking the machine on page 51.

• Slightly loosen the wheel nuts of the wheel you want to remove.

• Place a jack under the axle beam and make sure that it is secure.

• Be sure that the jack is firmly positioned.

• Raise the side of the axle from which you want to remove the wheel.

• Be sure that the machine is firmly positioned.

• Remove the wheel nuts.

• Remove the wheel.

Fitting the wheels

☞ Proceed as follows: • Place the wheel onto the wheel studs.

• Partially tighten all wheel nuts.

• Lower the raised axle.

• Tighten the wheel nuts to the correct tightening torque – see Tightening torques on page 148.

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Maintenance Electrical system Safety instructions

IMPORTANT! Use only 12-V power sources. Higher voltages will damage the electric components.

DO NOT interrupt voltage-carrying circuits at the battery terminals because of the danger of sparking.

Never place tools or other conductive items on the battery – danger of short circuit.

When connecting the battery leads, make sure the poles +/– are not reversed, reversing the poles will damage the electrical components.

• Disconnect the negative (–) battery cable from the battery before starting repair work on the electrical system.

Service and maintenance work at regular intervals Before driving the machine

☞ Check every time before driving the machine: • Light system.

• Signaling and warning system.

Weekly

☞ Check weekly: • Electric fuses – see Fuse no. on page 146.

• Battery terminal, battery cable, cable and ground connections.

• Charge condition of battery – see Battery on page 125.

Instructions for cables, fuses, bulbs, alternator Cables, bulbs and fuses

Follow these instructions: • Defective electrical system components must always be replaced by an authorized technician. The operator or other persons may change bulbs and fuses.

• Ensure good contact in leads and fuses.

• Blown fuses indicate overloading or short circuits. Check the electrical system before installing the new fuse.

• Only use fuses with the specified amperage – see Fuse no. on page 146.

Alternator

Follow these instructions: • Only test run the engine with the battery connected.

• When connecting the battery, make sure that the poles (+/–) are not reversed.

• Always disconnect the battery before completing welding work or connecting a quick battery charger.

• Replace defective charge indicators immediately – see Indicator (red) – alternator charge function 37, 43 on page 36.

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Maintenance Battery

-

DANGER!

+

Battery acid is highly caustic:

Risk of acid burn.

A

When recharging and/or working near the battery:

☞ Always wear goggles and protective clothing with long sleeves.

Fig. 131: Battery

If acid is spilt:

☞ Thoroughly rinse all affected surfaces immediately with plenty of water. ☞ Thoroughly wash any body part touched by the acid immediately with plenty of water and seek medical attention at once.

During charging in particular, but also during normal battery operation, an oxygen-hydrogen mixture is formed in the battery cells –

Risk of explosion. ☞ Avoid open flame and sparks in the vicinity of the battery, and do not

smoke. ☞ Do not jump-start the machine if the battery is frozen or if the acid level is low. The battery may rupture or explode.

☞ Always disconnect the negative pole (–) from the battery before starting repair work on the electrical system.

Battery A is located in the engine compartment, on the right side. The battery does not need any fluid to be refilled under normal operating conditions. However, have the battery checked at regular intervals to make sure the electrolyte level is between the MIN and MAX levels.

Checking the battery requires it to be removed and must be carried out by an authorized dealer.

Always follow the safety instructions for the battery.

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Maintenance General maintenance work Cleaning Cleaning the machine consists of three separate cleaning areas: • Machine interior.

• Machine exterior.

• Engine compartment.

The wrong cleaning equipment and agents can affect machine safety and undermine the health of the persons cleaning the machine.

Follow these instructions: General instructions for all areas of the machine

When using washing solvents • Ensure adequate room ventilation.

• Wear suitable protective clothing.

• DO NOT use flammable liquids, such as gasoline or diesel.

When using compressed air • Wear goggles and protective clothing.

• DO NOT aim the compressed air at the skin or at other people.

• DO NOT use compressed air for cleaning your clothing.

When using a high-pressure or steam jet cleaner • Cover electrical components and damping materials.

• Cover the vent filter on the hydraulic oil tank, the filler caps for fuel, hydraulic oil, etc.

• Protect the following components from moisture: • Engine.

• Electrical components (such as the alternator, etc.).

• Control devices and seals.

• Air intake filters, etc.

When using volatile and flammable anticorrosion agents and sprays • Ensure adequate room ventilation.

• DO NOT use unprotected lights or open flames.

• DO NOT smoke.

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Maintenance Cleaning inside the cab CAUTION! Never use high-pressure cleaners, steam jets, or high-pressure water to clean the inside of the cab. Water under high-pressure may: • Penetrate into the electrical systems and cause short circuits.

• Damage seals and disable the controls.

Use any of the following to clean the cab: • Broom • Vacuum cleaner • Damp cloth • Bristle brush • Water with mild soap solution Cleaning the seat belt

• Only clean the seat belt (DO NOT disconnect the seat belt from the machine) by using a mild soap solution; DO NOT use chemical agents because they may destroy the fabric.

WARNING! Debris or water on automatic seat belts (option) may affect winding –

Risk of personal injury. ☞ Only wind in the seat belt if it is both clean and dry.

Exterior of the machine

Use any of the following to clean the outside of the cab: • High-pressure cleaner • Steam jet

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Maintenance Engine compartment WARNING! Only clean the engine after it is turned off and stopped –

Risk of personal injury. ☞ Turn off the engine before cleaning.

CAUTION! When cleaning the engine with a water or steam jet:

☞ The engine must be cold. ☞ DO NOT point the jet directly at electrical sensors, such as the oil pressure sender.

Any humidity penetrating these sensors causes them to fail and leads to engine damage.

Checking bolted connections

IMPORTANT! Check all bolted connections regularly, even if they are not listed in the maintenance schedules.

Tighten all loose connections immediately – see Tightening torques on page 148 for the tightening torques.

Checking pivots and hinges

IMPORTANT! All mechanical pivot points on the machine (e.g., door hinges, joints) and fittings (e.g., door arresters) must be lubricated regularly, even if they are not listed in the lubrication plan.

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Maintenance Fluids and lubricants Component/ application

Engine/machine fluid

SAE grade Specification SAE 10W; EO103 SAE 20W20; EO203

Diesel engine

Engine oil2

SAE 30; EO303 HD-C 10W/40; EO1040B3 HD-C 15W/40; EO1540B3

Season/ temperature Below 23°F (-5°C) 14° to 50°F (-10° to 10°C) 41° to 86°F (5° to 30°C)

2.3 gal. (8.6 L)

Year-round 0.08 gal. (0.3 L)

Rear axle transfer gearbox Planetary drives – left and right, front and rear axle

Capacities1

4

Gearbox oil

Differential – front and rear axle

Engine oil2 Hydraulic oil tank

80W/90 API GL5 or SAE 90 LS (hypoid gear oil)

Year-round

SAE 5W/30

Up to -13°F (-25°C)

Biodegradable oil

0.66 gal. (2.5 L) each

SAE 5W/40; EO 0540B3 SAE 10W/40; EO 0540B3 SAE 15W/40; EO 1540B3

Hydraulic oil5

0.13 gal. (0.5 L) each

Up to 5°F (-15°C) Up to 14°F (-10°C)

About 17 gal. (65 L)

HVLPD 46 (HYD05303) (ATF 46) AVILUB Syntofluid 46 (bio-oil)

Year-round

PANOLIN HLP Synth 46 (bio-oil)

Grease nipples

Multipurpose grease

Lithium-based brand-name grease MPG-A3

Year-round

As required

Battery terminals

Acid-proof grease

SP-B3

Year-round

As required

Mounting of pins, shafts, etc.

Special grease

Optimoly paste “TA”6 White paste

Year-round

As required

Over 39°F (4°C) Below 39°F (4°C)

About 16 gal. (62 L)

Year-round

About 1.4 gal. (5.3 L)

Grade no. 2-D Fuel tank

7

Diesel fuel

Grade no. 1-D

Engine and hydraulic oil cooler

Coolant

Water + antifreeze; SP-C3

Washer system

Cleaning agent

Water + antifreeze

1.

2.

3.

4.

5.

6.

7.

About 0.4 gal. (1.5 L)

The capacities indicated are approximated values; only the oil level check is accurate for the correct oil level MIL-L-2104C; API CD/CE/CF4; CCMC-D4 Abbreviation for lubricants MIL-L-2105B; API-GL5 DIN 51 521 T3 250 gr tube, order no.: 0 00 441 32 10 DIN 51 601, min 45 cetane

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Maintenance Notes:

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“C” every 1500 hours (yearly)

● ● ● ●

● ● ● ● ● ● ● ● ● ●

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● ● ● ● ● ● ● ● ● ● ● ●

Maintenance

“B” every 500 hours2 2nd Inspection

1st Inspection1

at 100 hours

Oil and filter changes (

Delivery inspection

Work description For service and maintenance work on the attachment, also refer to the operation and maintenance manual of the attachment manufacturer.

“A” every 50 hours (weekly)

Maintenance schedule Model ML28 (overview)

Regular maintenance (daily)

Printed in U.S.A.

Maintenance schedule/service hours

):

Carry out the following oil and filter changes (check oil levels after test run):

131

• • • • • • • • • •

● ● ●

Engine oil Engine oil filter Fuel filter Fuel/water separator

Air filter insert 3, 4 replace safety cartridge every third time the air filter insert is replaced Gearbox oil in front and rear axle differentials and in rear axle gearbox Gearbox oil in front and rear axle planetary drives (left and right) Hydraulic oil5 Hydraulic oil filter insert Breather filter – hydraulic oil tank 4

Inspection work (

● ● ●

):

Check the following material. Refill if necessary: Engine oil Engine coolant 6 (also check antifreeze in autumn/winter and at temperatures below 39 °F (4 °C).)

Hydraulic oil Gearbox oil in front and rear axle differentials and in rear axle gearbox Gearbox oil in front and rear axle planetary drives (left and right) Check cooler for engine and hydraulic oil for contamination. Clean if necessary7 When using biodegradable oil: drain the condensation water in the hydraulic oil tank 5 Clean dust valve on air filter housing 3 V-belt: check condition and pre-tension. Tighten or replace if necessary Check the fuel/water separator. Drain water if necessary8 Check valve tip clearance (engine timing). Set if necessary Battery: check charge condition Heating: clean dust filter, replace every 1500 service hours if necessary9

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●

● ● ● ● ●

● ●

● ● ●

● ●

●

●

● ● ●

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Maintenance

918131/BP0207

• • • • • • • • • • • • •

● ●

● ●

●

● ● ● ● ● ● ● ● ●

● ● ● ● ● ● ● ● ●

● ● ● ● ● ● ● ● ●

●

●

●

●

1st Inspection1

● ●

Check screws and nuts or screw connections for tightness on the following assemblies/components. Tighten if necessary

132

• • • • • • • • •

Engine and engine bearing Steering system Hydraulic system Machine (pin locking) Axle mounting, axle suspension Counterweight (attachment) Attachment cap screws of propshafts Attachment cap screws of cab Wheel nuts

Electric system: check electric and ground connections, chafing on wiring harness, battery terminals Lubrication service (

):

10

Lubricate the following assemblies/components:

918131/BP0207

• Rear axle oscillating bearing • Front and rear axle planetary drive bearings (left and right) • Machine – see Lubrication points on page 119 • Lift frame bearing • Tilt rod bearing • Tilt lever bearing • Lift cylinder bearing • Tilt cylinder bearing • Quickhitch facility: bearing on lift frame • Hinges, joints and fittings (e.g., door arrester)

● ●

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● ●

● ●

● ●

● ● ● ● ● ●

● ● ● ● ● ● ●

● ● ● ● ● ● ●

● ● ● ● ● ● ●

● ● ● ● ● ● ●

Maintenance

●

“C” every 1500 hours (yearly)

●

“B” every 500 hours2 2nd Inspection

●

at 100 hours

• Check and set service and parking brake pads. Replace if necessary • Tire check (damage, air pressure, tread depth)

“A” every 50 hours (weekly)

Work description For service and maintenance work on the attachment, also refer to the operation and maintenance manual of the attachment manufacturer.

Delivery inspection

Maintenance schedule Model ML28 (overview)

Regular maintenance (daily)

Printed in U.S.A.

Maintenance schedule/service hours

“C” every 1500 hours (yearly)

● ● ●

“B” every 500 hours2 2nd Inspection

● ● ●

● ● ●

● ● ●

● ● ●

● ● ● ● ● ●

● ● ● ● ● ●

● ● ● ● ● ●

1st Inspection1

● ● ●

at 100 hours

Functional check (

“A” every 50 hours (weekly)

Work description For service and maintenance work on the attachment, also refer to the operation and maintenance manual of the attachment manufacturer.

Delivery inspection

Maintenance schedule Model ML28 (overview)

Regular maintenance (daily)

Printed in U.S.A.

Maintenance schedule/service hours

):

Check the function of the following assemblies/components. Rectify if necessary: • Service and parking brake • Steering system • Lights and electric system Leakage check (

):

Check for tightness, leakage and chafing: pipes, flexible lines and screw connections of the following assemblies and components. Correct if necessary: 133

● ● ● ● ● ●

• • • • • •

Air intake line (air filter – engine) Engine lubrication (engine – filter) Fuel lines Cooling system (coolant and hydraulic oil) Steering system (flexible lines and rams) Hydraulic system/machine (flexible lines and rams) 11

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

Work to be carried out after the first 100 service hours. This work must be carried out by an authorized dealer for warranty claims to be acknowledged.

Work to be carried out after the first 500 service hours (2nd Inspection) must be carried out by an authorized dealer for warranty claims to be acknowledged.

Replace filter insert as indicated on the filter housing every 1500 service hours or yearly.

When working in an acidic environment, replace the filter every 300 service hours.

When using biodegradable oil: drain the condensation water in the hydraulic oil tank every 500 service hours, or before the cold season if you have not passed 500 service hours.

Replace engine coolant every 2 years.

Depending on operation and dust conditions, it may necessary to clean the cooler more frequently.

Check every s/h and drain water.

Depending on operation and dust conditions, it may be necessary to replace the dust filter more frequently.

Lubricate attachment according to manufacturer's instructions.

Replace flexible lines every 6 years.

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Maintenance

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Maintenance

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Notes:

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Maintenance

Maintenance

Maintenance log

Company/ signature

Service hours

Date

After service hours

Maintenance schedule

Maintenance log

650

A

700

A

750

A

800

A

850

A

900

A

950

A

Company/ signature

Service hours

Date

The 1st and 2nd Inspections must be carried out by an authorized dealer for the warranty claims to be acknowledged. For information on maintenance material, consumables, and lubricants – see Fluids and lubricants on page 129.

Maintenance schedule

Check off the columns in the boxes below after the work is completed.

Maintenance log After service hours

Use the following table to record the maintenance and service work that you complete after a certain amount of service hours – see Maintenance schedule Model ML28 (overview) on page 131.

Delivery 50 100 150

A 1st Inspection A 1000 B

200

A 1050 A

250

A 1100 A

300

A 1150 A

350

A 1200 A

400

A 1250 A

450

A

500

B 2nd Inspection

1300 A

550

1350 A

A 1400 A

600

A

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Maintenance

1450 A

2300

A

1500 C yearly

2350

A

1550 A

2400

A

1600 A

2450

A

1650 A

2500

B

1700 A

2550

A

1750 A

2600

A

1800 C

2650

A

1850 A

2700

A

1900 A

2750

A

1950 A

ML28 A 0

2000 B

2850

A

2050 A

2900

A

2100 A

2950

A

2150 A

3000

C

2200 A

3050

A

2250 A

3100

A

Printed in U.S.A.

136

Company/ signature

Service hours

Date

Maintenance schedule

After service hours

Company/ signature

Service hours

Maintenance log

Date

Maintenance schedule

After service hours

Maintenance log

918131/BP0207

Maintenance

3150

A

4000 B

3200

A

4050 A

3250

A

4100 A

3300

A

4150 A

3350

A

4200 A

3400

A

4250 A

3450

A

4300 A

3500

B

4350 A

3550

A

4400 A

3600

A

4450 A

3650

A

4500 C

3700

A

4550 A

3750

A

4600 A

3800

A

4650 A

3850

A

4700 A

3900

A

4750 A

3950

A

Printed in U.S.A.

137

Company/ signature

Service hours

Date

Maintenance schedule

After service hours

Company/ signature

Service hours

Maintenance log

Date

After service hours

Maintenance schedule

Maintenance log

918131/BP0207

Maintenance Notes:

Printed in U.S.A.

138

918131/BP0207

Maintenance

Maintenance Maintenance decal Location: on inside of rear window.

Explanation of symbols on maintenance decals Symbol

Description Before starting maintenance work, read the safety instructions in the Operator’s Manual.

Before starting maintenance work, read the “Maintenance” section in the Operator’s Manual.

Check that the light system functions correctly.

Check tires for damage, pressure and tread depth.

Carry out a functional check and synchronize the steering system.

Carry out a functional check of the brake system.

Check hydraulic oil level. Fill up if necessary.

Check engine oil level. Fill up if necessary.

Check coolant level. Fill up if necessary.

Check cooler for engine coolant and hydraulic oil for contamination. Clean if necessary.

Check condition and initial tension of V-belt. Tighten or replace if necessary.

Leakage check: Check for tightness, leakage and chafing: pipes, flexible lines and screw connections. Correct if necessary.

Lubrication service: Lubricate the assemblies.

Printed in U.S.A.

139

918131/BP0207

0 00 435 30 89

Maintenance

10 h

Daily

50 h 341 02 0001 0004353089.eps

Printed in U.S.A.

140

918131/BP0207

Specifications

Specifications

Specifications Frame Sturdy steel frame, rubber-mounted engine.

Engine Engine Product

Yanmar diesel engine

Model

4TNV 88

Type

Water-cooled 4-cycle diesel engine

No. of cylinders

4

Displacement

134 in³ (2190 cm³)

Bore and stroke

3.5 x 3.5” (88 x 90 mm)

Output

38 hp (28 kW) @ 2400 rpm

Max. torque

97 –105 lb.-ft. (132 –143 Nm) @ 1600 rpm

Max. engine speed without load

2590 +/- 50 rpm

Idle engine speed

1050 +/- 25 rpm

Specific fuel consumption

319 g/hph (238 g/kWh)

Fuel injection system

Direct injection

Firing order

1–3–4–2

Starting aid

Glow plug (preheating time 10 – 15 seconds)

Max. inclined position (engine no longer supplied with oil): Exhaust values according to

Printed in U.S.A.

25° in all directions (Machine tilting limit is 20° lateral).

97/68/EC

141

918131/BP0207

Specifications Power train Variable displacement pump Type

Infinitely adjustable axial pistons

Displacement

0 – 1.7 in³/rev (0 – 28 cm³/rev)

Max. service pressure

5076 psi (350 bar)

Starting RPMs

1250 +100 rpm

Droop

2250 +100 rpm

Boost pump (integrated in variable displacement pump) Type

Gear

Displacement

0.5 in³/rev (8.4 cm³/rev) 435 psi (30 bar)

Charging/boost pressure

Electrohydraulic control (F – R on drive lever)

Driving direction Inching

Mechanical via brake inching pedal

Hydraulic motor Type

Axial piston motor

Displacement

3.4 in³/rev (55 cm³/rev) 0 – 12.4 mph (0 – 20 km/h), forward and reverse

Drive speed Tractive effort

5395 lbf (24.0 kN)

Transfer gearbox Type

Single-stage

Transmission ratio

1.8529

Axles Front axle (with 45% self-locking differential) Type

Rigid steering and drive axle

King-pin inclination

7°

Camber

1.5°

Steering angle

38°

Toe-in

0” (0 mm) 47” (1193 mm)1

Tread width Rear axle (with 45% self-locking differential) Type

Steering and drive axle, oscillating

King-pin inclination

7°

Oscillation angle

+/- 7°

Camber

-/ 1.5°

Steering angle

38°

Toe-in

0” (0 mm) 47” (1193 mm)1

Tread width 1.

Printed in U.S.A.

With tires 12.0-18

142

918131/BP0207

Specifications Brakes Service brake Type

Hydrostatic

Location

Drive (rear axle transfer gearbox)

Effect

Foot-operated hydrostatic brake system, braking effect on all wheels via cardan shaft

Parking Brake Design

Manual, mechanical disc brake

Location

Front axle gearbox input

Effect

On both axles via cardan shaft

Steering Steering Hydrostatic four-wheel steering with emergency steering feature

Type Steering mode

Four wheel steering Hydraulic pump, priority valve, servostat with safety valves, steering cylinder, selfsynchronizing in final position

Assemblies Max. pressure of hydraulic lines

2538 psi (175 bar)

Hydraulic pump

Gear pump Displacement 1.4 in³/rev (22.5 cm³/rev)

Steering angle

2 x 38°

Loader hydraulics Loader hydraulics Hydraulic pump displacement:

1.4 in³/rev (22.5 cm³/rev) ≡ 14 gal/min (52 L/min) at 2400 rpm

Control valve

3 sections ±73

Max. service pressure

3480

Secondary protection tilt cylinder Secondary protection lift cylinder Filter Hydraulic oil tank

Printed in U.S.A.

psi (240±5 bar)

Rod side 4061 psi (ML28 bar) Base side 1740 psi (120 bar) Rod side: Resuction Base side: 4351 psi (300 bar) Reflux suction filter (7 psi [0.5 bar] initial stress) 17 gal. (65 L)

143

918131/BP0207

Specifications Pilot control Pilot control pump = boost pump of hydraulic pump Displacement

0.5 in³/rev (8.4 cm ³/rev)

Charging/boost pressure

435 psi (30 bar), 2400 rpm

Pilot control unit Four-way lever – control of lift and tilt cylinders Electric control of lock cylinder or attachments via tip switches Lock against unintentional operation (for long-haul travel and transport)

Joystick

Lock lever

Additional high flow control circuit (option) Additional high flow control circuit

Printed in U.S.A.

Hydraulic pump Displacement: front and rear Max. service pressure

1.4 in³/rev (22.5 cm³/rev) 14 gal/min (52 L/min) at 2400 rpm 3481 psi (240 bar)

Hydraulic pump Displacement: front only Max. service pressure

2.0 in³/rev (32 cm³/rev) 20 gal/min (75 L/min) at 2400 rpm 2756 psi (190 bar)

Front Hydraulic connections Pressure line: Unpressurized reflux:

1 x nw 16 (red) 1 x nw 20 (blue)

Rear Hydraulic connections Pressure line: Unpressurized reflux:

1 x nw 12 (red) 1 x nw 16 (blue)

144

918131/BP0207

Specifications Electrical system Electrical system Alternator

12-V 55 A

Starter

12-V 1.9 hp (1.4 kW)

Battery

12-V 72 Ah

Socket (e.g. for cigarette lighter)

15 A

Fuse no.

Rated current

Protected circuit

F1

7.5 A

– High beam (left)

F2

7.5 A

– High beam (right)

F3

5A

– Parking light (left)

F4

5A

– Parking light (right)

F5

10 A

– Start

F6

25 A

– Additional lights

F7

25 A

– Lights

F8

7.5 A

– Low beam (left)

F9

7.5 A

– Low beam (right)

F10

5A

– Relays, indicators, cutoff solenoid

F11

15 A

– Wiper

F12

15 A

– Valves

F13

7.5 A

– Maneuvering

F14

30 A

– Fan, rear window heating

F15

7.5 A

– Turn indicator

F16

5A

– Radio

Fuse box in control lever base

F1

F8

F9

F2

F3

F4

F5

F6

F7

F10 F11 F12 F13 F14 F15 F16

34001b710_01.eps

Fig. 132: Fuse box

Printed in U.S.A.

145

918131/BP0207

Specifications Main fuse box with relays The main fuse box is located in the engine compartment, on the left side.

K33 K17

Fuse no.

Rated current (A)

Protected circuit

F17

80 A

– Main fuse

F18

40 A

– Preheating/start fuse (starter)

Relay no.

Protected circuit

K 16

– Preheating

K 17

– Start

K 33

– Cutoff solenoid

K16 F17 F18

Fig. 133: Main fuse box in the engine compartment

Relays The relays are installed in the control lever base under the switch panel (as seen from below the fuse board).

K1

K7

K31

K5

K12

K4

Switching relay no.

Protected circuit

K1

– High current relay – terminal 15

K3

– Solenoid valve – reverse maneuvering

K4

– Solenoid valve – forwards maneuvering

K5

– Front attachments

K6

– Turn indicator relay

K7

– Wipers

K 11

– Change-over (3rd control circuit)

K 12

– Change-over (3rd control circuit)

K 13

– Unlock (quickhitch facility)

K 14

– Lock (quickhitch facility)

K 31

– Time-lag relay 5 min (rear window heating)

K11 K3

K13 K14 K6

Fig. 134: Relays

Printed in U.S.A.

146

918131/BP0207

Specifications Tires Tire pressure

Tire size

1.

Wheel rims

Front

Rear

Wheel rim

Wheel offset

12.0-18 /12 PR

2.01

2.0

9x18

1.2” (30 mm) wheel offset

325/70 R18 113A8

3.01

2.5

9x18

2.7” (69 mm) wheel offset

Increase front tire pressure by 7.25 psi (0.5 bar) during pallet forks operation.

Weights Standard cab

Weights Curb weight

Open cab

7055 lbs. (3200 kg) 6878 lbs. (3120 kg)

Front axle load

2535 lbs. (1150 kg) 2447 lbs. (1110 kg)

Rear axle load

4519 lbs. (2050 kg) 4167 lbs. (1890 kg)

Gross weight rating

8378 lbs. (3800 kg)

Front axle weight rating

6063 lbs. (2750 kg)

Rear axle weight rating

6063 lbs. (2750 kg)

Max. authorized load for towing facility

5512 lbs. (2500 kg)

Noise levels Sound power level Measured value

100.5 dB (A)

Guaranteed value

102 dB (A)

Noise level in the cab (standard cab) (open cab and ROPS bar)

76 dB (A) 82 dB (A)

NOTE: Measurement of sound power level according to EC Directive 2000/14/EC. Noise level in the cab measured according to EC Directives 84/532/EEC, 89/514/EEC and 95/27/EEC. Measurements carried out on asphalt surface.

Printed in U.S.A.

147

918131/BP0207

Specifications Vibration Vibration Effective acceleration value for the upper extremities of the body

m < 2.5 ----2

Effective acceleration value for the body

m < 0.5 ----2

s

s

Coolant compound table Outside temperature Up to °F (°C) 39 (4) 14 (-10) -4 (-20) -13 (-25) -22 (-30)

Water % by volume 99 79 65 59 55

Coolant Anti-corrosion agent in³/gal. % by volume (cm³/ltr) 2.6 (10)

1

Antifreeze agent % by volume – 20 34 40 44

Tightening torques General torques Cap screw dimensions M4 M5 M6 M8 M10 M12 M14 M16 M18 M20 M22 M24 M27 M30 1.

Torques in lb-ft (Nm)1 8.8 10.9 12.9 2 (3) 3 (4) 4 (5) 4 (5.5) 6 (8) 7 (10) 7 (10) 10 (14) 12 (16) 17 (23) 25 (34) 30 (40) 34 (46) 49 (67) 58 (79) 58 (79) 85 (115) 100 (135) 92 (125) 136 (185) 162 (220) 144 (195) 214 (290) 251 (340) 207 (ML28) 295 (400) 347 (470) 291 (395) 413 (560) 487 (660) 398 (540) 561 (760) 656 (890) 502 (680) 715 (970) 848 (1150) 738 (1000) 1069 (1450) 1254 (1700) 996 (1350) 1438 (1950) 1696 (2300)

These values are valid for cap screws with untreated, non-lubricated surfaces.

Specific torques

Printed in U.S.A.

Description

Torque

Wheel nut

221±15 lb-ft (300 ±20 Nm)

Track-rod end (steering)

118 lb-ft (160 Nm)

Piston rod (steering cylinder/track rod)

184 lb-ft (250 Nm)

148

918131/BP0207

Specifications Loader unit Machine with bucket 1 Bucket capacity

0.71 yd³ (0.65 m³)

Tipping load

5159 lbs. (2340 kg)

Rated operating load

2579 lbs. (1170 kg)

Bucket width

65” (1650 mm)

Dump height

91” (2300 mm)

Pin height

119” (3020 mm)

Dump reach

10” (250 mm)

Scraping depth

2” (49 mm)

Tilt-back angle

45°

Dump angle

40°

Breakout force (lift cylinder)

6295 lbf (28.0 kN)

Breakout force (tilt cylinder)

6144 lbf (27.3 kN)

Fork arms (payloads stated for 24” [610 mm] load distance) Payload, safety factor 2.00:

2209 lbs. (1002 kg.) (standard cab) 2117 lbs. (960 kg.) (open cab)

Tipping load

3682 lbs. (1670 kg.)

Lift height

105” (2670 mm)

Movable payload in the transport position (safety factor 2.00): 1.

Printed in U.S.A.

2618 lbs. (1188 kg.)

Model ML28 with tires 10.5 – 18 and standard bucket..

149

918131/BP0207

Specifications Dimensions

34001b710_03.iso

8” (200)

98” (2490)

70” (1790)

92” (2340)

91” (2300)

111” (2820)

119” (3020)

10” (250)

34001b710_04.iso

64” (1620)

69” (1750)

49” (1240)

182” (4610)

65” (1650)

Fig. 135: Machine dimensions

Dimensions Overall length1

181” (4610 mm)

Overall height 2, 3 without cab

70” (1790 mm)

Overall height2 with cab

92” (2340 mm)

Overall height2 with cab and protective FOPS screen4

94” (2400 mm)

Overall height2 with cab and rotating beacon (option)

98” (2490 mm)

Overall height2 with ROPS bar (option)

94” (2400 mm)

Overall height2, 5 with ROPS bar folded down (option)

78” (1985 mm)

Overall width without bucket6

59” (1500 mm)

Overall width1

65” (1650 mm)

Ground clearance in the transport position of machine

8” (200 mm)

Ground clearance2 below rear axle gearbox

13” (320 mm)

Tread width, front/rear

47” (1193 mm)

Wheelbase

69” (1750 mm)

Turning radius7

96” (2430 mm)

1.

2.

3.

4.

5.

6.

7.

Printed in U.S.A.

With standard bucket.

With tires 10.5-18 (1” [25 mm] less with 12-16.5 tires).

Top edge of inside trim panel (behind operator's seat).

According to ISO 3449 category I. Measured at upper edge of pivot.

With outside mirrors folded in.

Measured at outer edge of tires.

150

918131/BP0207

Index

Index

A

M

Abbreviations ............................................................................................5 Additional rear lights ...............................................................................96 Air filter .................................................................................................111 Applications with lifting gear ...................................................................18 Attachment adapter Mounting on quickhitch ..................................................................101

Machine Fields of application .......................................................................... 9 Loading and transporting ................................................................ 22 Overview ...................................................................................... 7, 8 Maintenance Adding hydraulic oil ....................................................................... 115 Air filter cartridge ........................................................................... 112 Alternator ...................................................................................... 124 Biodegradable oil .......................................................................... 116 Bleeding the fuel system ............................................................... 106 Bulbs, fuses .................................................................................. 124 Checking the coolant level ............................................................ 110 Checking the engine oil level ........................................................ 107 Checking the hydraulic oil level ..................................................... 115 Cleaning with a high-pressure cleaner .......................................... 126 Cleaning with anticorrosion agents ............................................... 126 Cleaning with washing solvents .................................................... 126 Electrical system ........................................................................... 124 Engine and hydraulics cooling system .......................................... 109 Engine lubrication system ............................................................. 107 Filling up the coolant level ............................................................. 110 Fluids and lubricants ..................................................................... 129 Fuel system ................................................................................... 105 General maintenance work ........................................................... 126 Hydraulic pressure lines ................................................................ 117 Hydraulic system ........................................................................... 114 Instructions for cables, fuses, bulbs, alternator ............................. 124 Maintenance log ............................................................................ 135 Maintenance schedule .................................................................. 131 Pivots and hinges .......................................................................... 128 Scheduled maintenance ............................................................... 124 Screw connections ........................................................................ 128 Tire care ........................................................................................ 122 V-belt ............................................................................................. 113 Wheel change ............................................................................... 123 Multipurpose bucket operation ............................................................... 96

B Biodegradable oil ..................................................................................116 Brake/inching pedal ................................................................................48 Brakes Brake/inching pedal .........................................................................48

C Cab Removing the cab ...........................................................................68 Checklists ...............................................................................................30 Pre-delivery and Delivery ................................................................31 Start-up ............................................................................................40 Clearance height ....................................................................................68

D Decals on the outside of the machine ....................................................12 Designated use and exemption from liability ............................................5 Differential lock .......................................................................................51 Driving on public roads ...........................................................................46

F Fire extinguisher Fire extinguisher, location ...............................................................13 Fluids and lubricants ............................................................................129 Fork arms Adjusting distance ...........................................................................89 Lock levers ......................................................................................89 Overview .........................................................................................87 Functional check Air filter dust valve .........................................................................111

G General information ..................................................................................3

H Hazard warning system ..........................................................................56 Heating ...................................................................................................57 Hose burst valve (option) .......................................................................79 Hydraulic connections ............................................................................94

I Indicators ................................................................................................37 Interior light .............................................................................................56

J Jump-starting the engine ........................................................................45

L Legal regulations ....................................................................................12 Light system ...........................................................................................54 Load diagram .........................................................................................90 Load stabilizer (option) ...........................................................................52 Loader unit Checking the tilt position of the bucket ............................................80 Checking the transport position of the bucket .................................80 Depressurising quick couplers ........................................................74 Depressurizing quick couplers ........................................................74 Lowering with the engine turned off ................................................74 Re-installing .....................................................................................74 Lock cylinder ..........................................................................88, 93, 101 Lowering the loader unit with the engine turned off ................................74 Lubrication ............................................................................................119

Printed in U.S.A.

151

N

Noise levels .................................................................................. 12, 147

O

Operation ............................................................................................... 33 Cab (overview) ................................................................................ 34 Driving the machine ........................................................................ 46 Hose burst valve safety feature (option) ......................................... 79 Instrument panel, multifunctional lever and drive lever (overview) . 36 Load stabilizer (option) .................................................................... 52 Parking the machine ....................................................................... 51 Seat belt height setting ................................................................... 62 Starting the engine .......................................................................... 43 Operational safety .................................................................................. 15

P Pallet forks Picking up loads .............................................................................. 91 Transporting loads .......................................................................... 92 Parking brake ......................................................................................... 49 Power supply for electrically operated attachments (option) ................. 76

Q

Quickhitch facility ............................................................................ 93, 95 Fitting an attachment ............................................................... 88, 93 Removing an attachment ................................................................ 88 Unlocking the attachment ............................................................... 88

918131/BP0207

Index R Refueling ..............................................................................................105 Removing the multipurpose bucket from the quickhitch facility ..............95 Rotating beacon .....................................................................................55 Running-in period ...................................................................................39

Removing material/digging in hard soil ........................................... 84 Removing material/digging in soft soil ............................................ 83 Using pallet forks ............................................................................ 86 Working light (option) ............................................................................. 55

S Safety Decals .........................................................................................12 Safety instructions ..................................................................................15 Applications with lifting gear ............................................................18 Identification ......................................................................................6 Maintenance ....................................................................................25 Specific hazards ..............................................................................27 Trailers and attachments .................................................................23 Transport .........................................................................................23 Seat adjustment .....................................................................................60 Backrest adjustment ........................................................................61 Horizontal adjustment ......................................................................61 Weight setting ..................................................................................60 Seat belt .................................................................................................62 Seat belt height setting ...........................................................................62 Service brake .........................................................................................48 Specifications .......................................................................................141 Axles ..............................................................................................142 Brakes ...........................................................................................143 Coolant compound table ...............................................................148 Electrical system ...........................................................................145 Engine ...........................................................................................141 Frame ............................................................................................141 Loader unit ....................................................................................149 Noise levels ...................................................................................147 Pilot control ....................................................................................144 Power train ....................................................................................142 Steering .........................................................................................143 Tightening torques .........................................................................148 Vibration ........................................................................................148 Weights .........................................................................................147 Stability ............................................................................................ 88, 95 Steering ..................................................................................................47 Synchronous wheel position ...................................................................47

T Taking into service Checklist ..........................................................................................40 Running-in period ............................................................................39 Safety instructions ...........................................................................39 Tire care ...............................................................................................122 Towing and transporting the machine ....................................................20 Transport ................................................................................................81 Turn indicator .........................................................................................56

V Ventilation ..............................................................................................57 Ventilation, fresh air .........................................................................57

W Washer system Tank with windshield washer pump .................................................58 Wheel change ......................................................................................123 Windshield washer system .....................................................................58 Windshield wipers ..................................................................................58 Working Freeing the wheel loader .................................................................85 Grading ............................................................................................85 Loading heaped material .................................................................84 Loading loose material ....................................................................81

Printed in U.S.A.

152

918131/BP0207

TORQUE SPECIFICATIONS Note: Use these torque values when tightening hardware (excluding: locknuts and self-tapping, thread forming and sheet metal screws) unless specified otherwise.

Hydraulic fittings with various seals (light application). All torque values are in lb.-ft. (Nm) unless marked otherwise.

Straight pipe fitting with thread and screwed plug (GE) Non-return valve Identification aid Thread with elastic seal outside Ø Sealing washer Elastic seal O-ring M10X1.0

7 (9)

13 (18)

11 (15)

13 (18)

0.4 in. (10 mm)

M12X1.5 M14X1.5

15 (20) 26 (35)

18 (25) 33 (45)

18 (25) 26 (35)

18 (25) 26 (35)

0.5 in. (12 mm) 0.6 in. (14 mm)

M16X1.5

33 (45)

41 (55)

30 (40)

37 (50)

0.6 in. (16 mm)

M18X1.5

41 (55)

52 (70)

33 (45)

52 (70)

0.7 in. (18 mm)

M22X1.5 M27X2.0

48 (65) 66 (90)

92 (125) 133 (180)

44 (60) 74 (100)

92 (125) 107 (145)

0.9 in. (22 mm) 1.0 in. (27 mm)

M33X2.0

111 (150)

229 (310)

118 (160)

155 (210)

1.3 in. (33 mm)

M42X2.0

177 (240)

332 (450)

155 (210)

266 (360)

1.7 in. (42 mm)

M48X2.0 G1/8A

214 (290) 7 (9)

398 (540) 13 (18)

192 (260) 11 (15)

398 (540) 13 (18)

1.9 in. (48 mm) 0.4 in. (9.73 mm)

G1/4A

26 (35)

26 (35)

22 (30)

26 (35)

0.5 in. (13.16 mm)

G3/8A

33 (45)

52 (70)

33 (45)

37 (50)

0.7 in. (16.66 mm)

G1/2A G3/4A

48 (65) 66 (90)

66 (90) 133 (180)

41 (55) 74 (100)

48 (65) 103 (140)

0.8 in. (20.96 mm) 1.0 in. (26.44 mm)

G1A

111 (150)

229 (310)

118 (160)

140 (190)

1.3 in. (33.25 mm)

G1 1/4A

177 (240)

332 (450)

155 (210)

266 (360)

1.7 in. (41.91 mm)

G1 1/2A

214 (290)

398 (540)

192 (260)

398 (540)

1.9 in. (47.80 mm)

Hydraulic fittings with various seals (heavy application). All torque values are in lb.-ft. (Nm) unless marked otherwise.

Straight pipe fitting with thread and screwed plug (GE) Sealing washer

Elastic seal

O-ring

Non-return valve with elastic seal

Identification aid outside Ø

M12X1.5 M14X1.5

15 (20) 26 (35)

26 (35) 41 (55)

26 (35) 33 (45)

26 (35) 33 (45)

0.5 in. (12 mm) 0.6 in. (14 mm)

M16X1.5

33 (45)

52 (70)

41 (55)

41 (55)

0.6 in. (16 mm)

M18X1.5

41 (55)

66 (90)

52 (70)

52 (70)

0.7 in. (18 mm)

M20X1.5 M22X1.5

41 (55) 48 (65)

92 (125) 100 (135)

59 (80) 74 (100)

74 (100) 92 (125)

0.8 in. (20 mm) 0.9 in. (22 mm)

M27X2.0

66 (90)

133 (180)

125 (170)

100 (135)

1.0 in. (27 mm)

M33X2.0

111 (150)

229 (310)

229 (310)

155 (210)

1.3 in. (33 mm)

M42X2.0 M48X2.0

177 (240) 214 (290)

332 (450) 398 (540)

243 (330) 310 (420)

266 (360) 398 (540)

1.7 in. (42 mm) 1.9 in. (48 mm)

G1/8A

26 (35)

41 (55)

33 (45)

33 (45)

0.5 in. (13.16 mm)

G1/4A

33 (45)

59 (80)

44 (60)

44 (60)

0.7 in. (16.66 mm)

G3/8A G1/2A

48 (65) 66 (90)

85 (115) 133 (180)

55 (75) 125 (170)

74 (100) 107 (145)

0.8 in. (20.96 mm) 1.0 in. (26.44 mm)

G3/4A

111 (150)

229 (310)

229 (310)

192 (260)

1.3 in. (33.25 mm)

G1A

177 (240)

332 (450)

243 (330)

266 (360)

1.7 in. (41.91 mm)

G1 1/4A

214 (290)

398 (540)

310 (420)

398 (540)

1.9 in. (47.80 mm)

Thread

With coarse-pitch thread. All torque values are in lb.-ft. (Nm) unless marked otherwise.

Thread

Threads according to DIN 912, DIN 931, DIN 933, etc.

8.8

10.9

Threads according to DIN 7984

12.9

8.8

10.9

M5 M6

4.1 (5.5) 7 (10)

6 (8) 10 (14)

7 (10) 13 (17)

4 (5) 6.3 (8.5)

5 (7) 9 (12)

M8

18 (25)

26 (35)

31 (42)

15 (20)

22 (30)

M10

33 (45)

48 (65)

59 (80)

30 (40)

44 (59)

M12 M14

64 (87) 100 (135)

81 (110) 133 (180)

108 (147) 170 (230)

51 (69) 81 (110)

74 (100) 118 (160)

M16

155 (210)

203 (275)

258 (350)

125 (170)

184 (250)

M18

207 (280)

302 (410)

354 (480)

181 (245)

254 (345)

M20 M22

302 (410) 406 (550)

420 (570) 575 (780)

509 (690) 686 (930)

251 (340) 339 (460)

361 (490) 487 (660)

M24

524 (710)

738 (1000)

878 (1190)

435 (590)

620 (840)

M27

767 (1040)

1092 (1480)

1305 (1770)

642 (870)

922 (1250)

M30

1047 (1420)

1482 (2010)

1770 (2400)

885 (1200)

1254 (1700)

With fine-pitch thread. All torque values are in lb.-ft. (Nm) unless marked otherwise.

Thread

Threads according to DIN 912, DIN 931, DIN 933, etc.

8.8

10.9

Threads according to DIN 7984

12.9

8.8 16 (22) 32 (43)

10.9

M8X1.0 M10X1.0

18 (25) 37 (50)

27 (37) 55 (75)

32 (43) 65 (88)

24 (32) 48 (65)

M10X1.25

36 (49)

52 (71)

61 (83)

31 (42)

46 (62)

M12X1.25

64 (87)

96 (130)

111 (150)

55 (75)

81 (110)

M12X1.5 M14X1.5

61 (83) 100 (135)

92 (125) 148 (200)

107 (145) 173 (235)

53 (72) 89 (120)

77 (105) 129 (175)

M16X1.5

155 (210)

229 (310)

266 (360)

133 (180)

195 (265)

M18X1.5

232 (315)

332 (450)

391 (530)

199 (270)

284 (385)

M20X1.5 M22X1.5

325 (440) 435 (590)

465 (630) 620 (840)

538 (730) 723 (980)

277 (375) 369 (500)

391 (530) 524 (710)

M24X2.0

546 (740)

789 (1070)

922 (1250)

465 (630)

664 (900)

M27X2.0

811 (1100)

1143 (1550)

1328 (1800)

679 (920)

959 (1300)

M30X2.0

1106 (1500)

1586 (2150)

1844 (2500)

959 (1300)

1364 (1850)

WARNING THIS OPERATOR'S MANUAL IS PROVIDED FOR OPERATOR USE DO NOT REMOVE FROM THIS MACHINE Do not start, operate or work on the machine until you carefully read and thoroughly understand the contents of this Operator’s Manual.

Failure to follow safety, operating and maintenance instructions can result in serious injury to the operator or bystanders, poor operation, and costly breakdowns.

If you have any questions on proper operation, adjustment or maintenance of the machine, contact your dealer or the Mustang Manufacturing Company Service Department before starting or continuing operation.

California Proposition 65 Warnings: Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer and birth defects and other reproductive harm.

Battery post, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and birth defects and other reproductive harm. Wash hands after handling battery.

918131/BP0207

© 2007 MUSTANG MANUFACTURING COMPANY, INC. All rights reserved.

Printed in U.S.A.